AWS B4.0-2007 Standard Methods for Mechanical Testing OfWelds

AWS B4.0:2007An American National Standard

Standard Methodsfor MechanicalTesting of Welds

Copyright American Welding Society Provided by IHS under license with AWS

Not for ResaleNo reproduction or networking permitted without license from IHS

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550 N.W. LeJeune Road, Miami, FL 33126

AWS B4.0:2007An American National Standard

Approved by theAmerican National Standards Institute

May 2, 2007

Standard Methods for

Mechanical Testing of Welds

7th Edition

Supersedes ANSI/AWS B4.0-98

Prepared by theAmerican Welding Society (AWS) B4 Committee on Mechanical Testing of Welds

Under the Direction of theAWS Technical Activities Committee

Approved by theAWS Board of Directors

AbstractMechanical test methods that are applicable to welds and welded joints are described. For each testing method, informationis provided concerning applicable American National Standards Institute (ANSI), American Society for Testing andMaterials (ASTM), and American Petroleum Institute (API) documents; the required testing apparatus, specimen preparation,procedure to be followed, and report requirements are also described.



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International Standard Book Number: 978-0-87171-071-0American Welding Society

550 N.W. LeJeune Road, Miami, FL 33126© 2007 by American Welding Society

All rights reservedPrinted in the United States of America

Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyrightowner.

Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, oreducational classroom use only of specific clients is granted by the American Welding Society provided that the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:<www.copyright.com>.



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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, ormade part of, documents that are included in federal or state laws and regulations, or the regulations of other govern-mental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWSstandards must be approved by the governmental body having statutory jurisdiction before they can become a part ofthose laws and regulations. In all cases, these standards carry the full legal authority of the contract or other documentthat invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirementsof an AWS standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whetherspecial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or relianceon this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any informationpublished herein.

In issuing and making this standard available, AWS is neither undertaking to render professional or other services for oron behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek theadvice of a competent professional in determining the exercise of reasonable care in any given circumstances.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard acceptany and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement ofany patent or product trade name resulting from the use of this standard.

Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are postedon the AWS web page (www.aws.org).

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society,Attention: Managing Director, Technical Services Division, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex B).With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered.These opinions are offered solely as a convenience to users of this standard, and they do not constitute professionaladvice. Such opinions represent only the personal opinions of the particular individuals giving them. These individualsdo not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations ofAWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS B4 Committee on Mechanical Testing of Welds. It must bereviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations,additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should beaddressed to AWS Headquarters. Such comments will receive careful consideration by the AWS B4 Committee onMechanical Testing of Welds and the author of the comments will be informed of the Committee’s response to thecomments. Guests are invited to attend all meetings of the AWS B4 Committee on Mechanical Testing of Welds toexpress their comments verbally. Procedures for appeal of an adverse decision concerning all such comments areprovided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained fromthe American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.



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Dedication

Henry Hahn

The AWS B4 Committee on Mechanical Testing ofWelds dedicates this edition of AWS B4.0, StandardMethods for the Mechanical Testing of Welds, to thememory of Henry H. Hahn. Henry was an activeand productive member and past Chair of theAWS B4 Committee on Mechanical Testing ofWelds, a past Chair of ISO/TC44/SC5, past Chairof ISAC-05, and a former member of the AWSTechnical Activities Committee and AWS Inter-national Standards Activities Committee.



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Personnel

*Deceased

AWS B4 Committee on Mechanical Testing of WeldsR. J. Wong, Chair Naval Surface Warfare Center

R. F. Waite, 1st Vice Chair ConsultantT. McGaughy, 2nd Vice Chair Edison Welding Institute

B. C. McGrath, Secretary American Welding SocietyJ. R. Crisci ConsultantD. A. Fink The Lincoln Electric Company*H. Hahn Consultant

J. M. Morse The Lincoln Electric CompanyJ. H. Smith Consultant

L. Van Leaven Electric BoatK. Zerkle Hobart Institute

Advisors to the AWS B4 Committee on Mechanical Testing of Welds

J. J. DeLoach, Jr. Naval Surface Warfare CenterD. B. Holliday Northrop Grumman Corporation

E. L. Lavy ConsultantL. Li Utah State University

H. W. Mishler ConsultantG. R. Pearson Anderson Laboratories

A. G. Portz ConsultantW. W. St. Cyr, II NASA



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Foreword

This foreword is not part of AWS B4.0:2007, Standard Methods for MechanicalTesting of Welds, but is included for informational purposes only.

This standard covers the common tests for the mechanical testing of welds. They are defined and illustrated in sectionsrelated to tension tests, shear tests, bend tests, fracture toughness tests, hardness tests, break tests (nick and fillet welds),selected weldability tests and process specific tests (stud weld tests and resistance weld tests).

This document extensively uses American Society for Testing and Materials (ASTM) Standard Methods and specifieshow to use these methods when testing weldments. It takes into consideration the variations in properties that can occurbetween different regions (base metal, heat-affected zone, and weld metal) of a weldment.

Methods of hardness testing and mechanical property tests for base metals are covered by ASTM standards or theindividual material specification. The joint tests for brazements are covered in ANSI/AWS C3.2, Standard Methods forEvaluating the Strength of Brazed Joints in Shear. Additional information on the mechanical testing of welded jointsmay be obtained from the AWS Welding Handbook, Volume 1, which describes selected weldability test methods.

AWS B4.0:2007, Standard Methods for the Mechanical Testing of Welds, is the seventh edition of the document initiallypublished in 1942. The second edition (1974) incorporated metric conversions and the third edition (1977) incorporatedminor changes. The fourth edition (1985) added the plane-strain fracture toughness test and the fifth edition (1992)added hardness testing and stud weld tests, and organized the tests by weld type. The sixth edition (1998) added six newweldability tests, and the current edition includes three new weldability tests (WIC, trough, and GBOP) and resistanceweld tests. Previous editions of the document are as follows:

AWS A4.0-42, Standard Methods for Mechanical Testing of Welds

AWS B4.0-74, Standard Methods for Mechanical Testing of Welds





Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,AWS B4 Committee on Mechanical Testing of Welds, American Welding Society, 550 N.W. LeJeune Road, Miami, FL33126.



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Table of Contents

Page No.

Dedication ....................................................................................................................................................................vPersonnel ....................................................................................................................................................................viiForeword .....................................................................................................................................................................ixList of Figures........................................................................................................................................................... xiii

1. Scope .....................................................................................................................................................................1

2. Normative References .........................................................................................................................................1

3. Terms and Definitions.........................................................................................................................................1

4. Tension Tests .......................................................................................................................................................14.1 Scope ..........................................................................................................................................................14.2 Normative References ................................................................................................................................24.3 Definitions and Symbols ............................................................................................................................24.4 Summary of Method...................................................................................................................................24.5 Significance ................................................................................................................................................24.6 Apparatus....................................................................................................................................................24.7 Specimens...................................................................................................................................................24.8 Procedure....................................................................................................................................................34.9 Report .........................................................................................................................................................44.10 Commentary ...............................................................................................................................................4

5. Shear Tests .........................................................................................................................................................115.1 Scope ........................................................................................................................................................115.2 Normative References ..............................................................................................................................115.3 Summary of Method.................................................................................................................................115.4 Significance ..............................................................................................................................................115.5 Apparatus..................................................................................................................................................115.6 Specimens.................................................................................................................................................115.7 Procedure..................................................................................................................................................115.8 Report .......................................................................................................................................................125.9 Commentary .............................................................................................................................................12

6. Bend Tests ..........................................................................................................................................................156.1 Scope ........................................................................................................................................................156.2 Normative References ..............................................................................................................................156.3 Definitions and Symbols ..........................................................................................................................156.4 Summary of Method.................................................................................................................................156.5 Significance ..............................................................................................................................................156.6 Apparatus..................................................................................................................................................156.7 Specimens.................................................................................................................................................166.8 Procedure..................................................................................................................................................166.9 Report .......................................................................................................................................................176.10 Commentary .............................................................................................................................................17

7. Fracture Toughness Tests.................................................................................................................................287.1 Scope ........................................................................................................................................................28



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7.2 Normative References ..............................................................................................................................287.3 Summary of Method.................................................................................................................................287.4 Significance ..............................................................................................................................................287.5 Apparatus..................................................................................................................................................287.6 Specimens.................................................................................................................................................297.7 Procedure..................................................................................................................................................297.8 Report .......................................................................................................................................................29

8. Hardness Tests...................................................................................................................................................378.1 Scope ........................................................................................................................................................378.2 Normative References ..............................................................................................................................378.3 Summary of Method.................................................................................................................................378.4 Significance ..............................................................................................................................................378.5 Apparatus..................................................................................................................................................378.6 Specimens.................................................................................................................................................378.7 Procedure..................................................................................................................................................388.8 Report .......................................................................................................................................................38

9. Break Tests (Nick and Fillet Weld) .................................................................................................................399.1 Nick Break Test ........................................................................................................................................399.2 Fillet Weld Break Test..............................................................................................................................48

10. Weldability Testing ...........................................................................................................................................5210.1 Controlled Thermal Severity (CTS) Test .................................................................................................5310.2 Cruciform Test..........................................................................................................................................6010.3 Implant Test..............................................................................................................................................6710.4 Lehigh Restraint Test ...............................................................................................................................7210.5 Varestraint Test ........................................................................................................................................7610.6 Oblique Y-Groove Test ............................................................................................................................8210.7 Welding Institute of Canada (WIC) Test..................................................................................................8810.8 Trough Test ..............................................................................................................................................9210.9 Gapped Bead On Plate (GBOP) Test .......................................................................................................97

11. Process Specific Tests ......................................................................................................................................10011.1 Stud Weld Test .......................................................................................................................................10011.2 Resistance Welding Test ........................................................................................................................103

Annex A (Informative)—Bibliography....................................................................................................................131Annex B (Informative)—Guidelines for the Preparation of Technical Inquiries.....................................................133List of AWS Documents on the Mechanical Testing of Welds ...............................................................................135



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List of Figures

Figure Page No.

Tension Tests4.1 Round Tensile Specimens............................................................................................................................54.2 Transverse Rectangular Tension Test Specimen (Plate) .............................................................................74.3 Longitudinal Tension Test Specimens (Plates) ...........................................................................................84.4 Reduced Rectangular Section Tension Specimens for Pipe ........................................................................94.5 Full Section Tension Specimen for Pipe ...................................................................................................10

Fillet Weld Shear Tests5.1 Longitudinal Fillet Weld Shear Specimen.................................................................................................135.2 Transverse Fillet Weld Shear Specimen....................................................................................................145.3 Shear Strength Calculation ........................................................................................................................14

Bend Tests6.1 Typical Bottom Ejecting Guided Bend Test Fixture .................................................................................186.2 Typical Bottom Guided Bend Test Fixture ...............................................................................................196.3 Typical Wraparound Guided Bend Test Fixture .......................................................................................206.4 Transverse Side Bend Specimens (Plate) ..................................................................................................216.5 Transverse Face Bend and Root Bend Specimen (Plate) ..........................................................................226.6 Transverse Face Bend and Root Bend Specimens (Pipe)..........................................................................236.7 Longitudinal Face Bend and Root Bend Specimen (Plate) .......................................................................246.8 Fillet Weld Root Bend Test Specimen ......................................................................................................256.9 Surfacing Weld Face Bend and Side Bend Specimen ...............................................................................266.10 Longitudinal Guided Fillet Weld Bend Test .............................................................................................27

Fracture Toughness Tests7.1 Charpy V-Notch Impact Specimen............................................................................................................307.2 Dynamic Tear Test Specimen, Anvil Supports, and Striker......................................................................317.3 Compact Tension Fracture Toughness Specimen......................................................................................327.4 Standard Drop Weight Nil-Ductility Temperature Test Specimen ...........................................................337.5 Orientation of Weld Metal Fracture Toughness Specimens in a Double-Groove Weld

Thick Section Weldment ...........................................................................................................................347.6 Crack Plane Orientation Code for Compact Tension Specimens from Welded Plate...............................347.7 Recommended Ratio of Weld Metal to Specimen Thickness for Weld-Metal Fracture

Toughness Specimen (Compact Tension Specimen) ................................................................................357.8 Suggested Data Sheet for Drop Weight Test.............................................................................................36

Nick-Break Tests9.1.1 Nick-Break Testing Fixture Made Out of 6 in (152 mm) Pipe..................................................................419.1.2 Nick-Break Test Using Vise......................................................................................................................429.1.3 Testing of Fillet Welded Specimens..........................................................................................................429.1.4 Nick-Break Test Specimen ........................................................................................................................439.1.5 Specimen for Flash Butt Welds .................................................................................................................449.1.6 Specimens for Nick-Break Test of Branch Joint Connections ..................................................................459.1.7 Pipe Sleeve Test Specimen........................................................................................................................469.1.8 Fillet Welded Plate Specimens ..................................................................................................................47

Fillet Weld Break Tests9.2.1 Fillet Weld Break Specimen for Procedure Qualification.........................................................................49



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9.2.2 Fillet Weld Break Specimen for Primer Coated Materials........................................................................499.2.3 Fillet Weld Break Specimen for Galvanized Materials .............................................................................509.2.4 Fillet Weld Break Specimen for Welder Qualification .............................................................................509.2.5 Fillet Weld Break Specimen for Tack Welder Qualification ....................................................................519.2.6 Method of Testing Fillet Weld Break Specimen .......................................................................................51

Weldability Testing

Controlled Thermal Severity (CTS) Test10.1.1 Fixture Used to Position CTS Specimen for Welding...............................................................................5510.1.2 CTS Test Specimen ...................................................................................................................................5610.1.3 Cooling Bath Arrangement for CTS Test..................................................................................................5710.1.4 Sectioning of CTS Specimen.....................................................................................................................5810.1.5 Typical Location of Microhardness Impressions ......................................................................................5810.1.6 Suggested Data Sheet for CTS Test...........................................................................................................59

Cruciform Test10.2.1 Cruciform Test Assembly..........................................................................................................................6210.2.2 Locations of Specimens for Examination of Cracks in Cruciform Test....................................................6310.2.3 Schematic Illustration of the Attached Plate in the Slotted Cruciform Specimen.....................................6310.2.4 Sectioning for the Longitudinal Notch ......................................................................................................6410.2.5 Sectioning for the Transverse Notch .........................................................................................................6410.2.6 Location of Metallographic Specimens for Examination of Cracks in the Slotted Cruciform Test..........6510.2.7 Suggested Data Sheet for Cruciform Test .................................................................................................66

Implant Test10.3.1 Implant Test Specimen and Fixture...........................................................................................................6910.3.2 Typical Data for Implant Test Series.........................................................................................................7010.3.3 Suggested Data Sheet for Implant Test .....................................................................................................71

Lehigh Restraint Test10.4.1 Lehigh Restraint Weld-Metal Cracking Test Specimen............................................................................7410.4.2 Suggested Data Sheet for Lehigh Test.......................................................................................................75

Varestraint Test10.5.1 Varestraint Test Fixture and Specimen......................................................................................................7910.5.2 Auxiliary Bending Plates...........................................................................................................................8010.5.3 Typical Indications on Top Surface of Test Weld.....................................................................................8010.5.4 Suggested Data Sheet for Varestraint Test ................................................................................................81

Oblique Y-Groove Test10.6.1 Oblique Y-Groove Test Assembly ............................................................................................................8410.6.2 Oblique Y-Groove Test Weld Configuration ............................................................................................8510.6.3 Suggested Data Sheet for Oblique Y-Groove Test....................................................................................87

Welding Institute of Canada (WIC) Test10.7.1 Schematic Illustration of the WIC Test Assembly ....................................................................................9010.7.2 Illustration of the Straight Y Joint Design for the WIC Specimen............................................................9010.7.3 Illustration of the Oblique Y Joint Design for the WIC Specimen............................................................9010.7.4 Suggested Data Sheet for WIC Test ..........................................................................................................91

Trough Test10.8.1 Trough Test Specimen...............................................................................................................................9510.8.2 Location of Weld Starts, Stops, and Tension Test Specimens (Side View)..............................................9510.8.3 Suggested Data Sheet for Trough Test ......................................................................................................96

Gapped Bead On Plate (GBOP) Test10.9.1 Specimen Dimensions and Test Set-Up ....................................................................................................99



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Stud Weld Tests11.1.1 Equipment for Bend Tests for Welded Studs........................................................................................10111.1.2 Equipment for Applying a Tensile Load to a Welded Stud Using Torque ...........................................102

Resistance Weld Tests11.2.1 Peel Test Specimen ...............................................................................................................................11011.2.2 Peel Test ................................................................................................................................................11111.2.3 Measurement of a Weld Button Resulting from the Peel Test..............................................................11111.2.4 Bend Test Specimen..............................................................................................................................11211.2.5 Spot Weld Chisel Test...........................................................................................................................11311.2.6 Specimen for Tension Shear Test and Tension Shear Impact Test.......................................................11411.2.7 Twisting Angle γ at Fracture in Tension Shear Test .............................................................................11511.2.8 Cross-Tension Test Specimens .............................................................................................................11611.2.9 Fixture for Cross-Tension Test [for Thicknesses up to 0.19 in. (4.8 mm)] ..........................................11711.2.10 Fixture for Cross-Tension Test [for Thicknesses 0.19 in. (4.8 mm) and Over]....................................11811.2.11 Specimen for U Specimen Tension Test and U Specimen Shear Impact Test .....................................11911.2.12 U-Tension Test Jig ................................................................................................................................12011.2.13 Pull Test (90° Peel Test) .......................................................................................................................12111.2.14 Test Specimen and Typical Equipment for Torsion-Shear Test ...........................................................12211.2.15 Drop-Impact Test Specimen..................................................................................................................12311.2.16 Drop-Impact Test Machine ...................................................................................................................12411.2.17 Test Fixture for Shear-Impact Loading Test .........................................................................................12411.2.18 Test Fixture for Tension-Impact Loading Test .....................................................................................12511.2.19 Fatigue Testing Machine.......................................................................................................................12611.2.20 Pillow Test for Seam Welds..................................................................................................................12711.2.21 Suggested Data Sheet for Resistance Spot and Projection Welding.....................................................12811.2.22 Suggested Data Sheet for Resistance Seam Welding............................................................................129



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1. Scope

This specification establishes standard methods formechanical testing of welds. The significance of eachtest, test apparatus, preparation of the test specimens, andthe test procedure are described. Example test resultssheets are provided.

It is beyond the scope of this document to define therequired mechanical properties or acceptance criteria forthe weld metal.

This standard makes sole use of U.S. Customary Units.Approximate mathematical equivalents in the Interna-tional System of Units (SI) are provided for comparisonin parentheses or in appropriate columns in tables andfigures.

Safety and health issues and concerns are beyond thescope of this standard and therefore are not fullyaddressed herein. Safety and health information is availablefrom other sources, including, but not limited to, ANSIZ49.1, Safety in Welding, Cutting, and Allied Processes,and applicable federal, state, and local regulations.

2. Normative References

The following standards contain provisions which,through reference in this text, constitute mandatory pro-visions of this AWS standard. For undated references,the latest edition of the referenced standard shall apply.For dated references, subsequent amendments to, or revi-sions of, any of these publications do not apply.

AWS documents:1

AWS A1.1, Metric Practice Guide for the WeldingIndustry;

1 AWS standards are published by the American Welding Society,550 N.W. LeJeune Road, Miami, FL 33126.

AWS A2.4, Standard Symbols for Welding, Brazingand Nondestructive Examination; and

AWS A3.0, Standard Welding Terms and DefinitionsIncluding Terms for Adhesive Bonding, Brazing, Soldering,Thermal Cutting, and Thermal Spraying.

3. Terms and DefinitionsThe welding terms used in this standard are in accor-dance with AWS A3.0, Standard Welding Terms andDefinitions, Including Terms for Adhesive Bonding, Braz-ing, Soldering, Thermal Cutting, and Thermal Spraying.

4. Tension Tests4.1 Scope. This clause covers the tension testing ofwelded joints. It does not specify required properties oracceptance criteria. When this standard is used as a por-tion of specification for a welded structure or assemblyor for qualification, the following information shall befurnished:

(1) The specific type(s) and number of specimensrequired,

(2) Base metal specification/identification,

(3) Filler material specification/identification,

(4) The anticipated property values and whether theyare maximum or minimum requirements,

(5) Location and orientation of the specimens,

(6) Report form when required, and

(7) Postweld thermal or mechanical processing treat-ments, as applicable.

This standard is applicable to the following, when specified:

(1) Qualification of materials and welding proce-dures where specified mechanical properties arerequired,

Standard Methods forMechanical Testing of Welds



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(2) Information as a basis for acceptance and manu-facturing quality control where mechanical properties arerequested, and

(3) Research and development.

4.2 Normative References. The following standardscontain provisions which, through reference in this text,constitute mandatory provisions of this test. For undatedreferences, the latest edition of the referenced standardshall apply. For dated references, subsequent amend-ments to, or revisions of, any of these publications do notapply.

ASME Documents:2

ASME B46.1, Surface Texture, Surface Roughness,Waviness and Lay

ASTM Documents:3

ASTM E 4, Standard Practices for Force Verificationof Testing Machines

ASTM E 8, Standard Methods for Tension Testing ofMetallic Materials

ASTM B 557, Standard Test Methods for TensionTesting Wrought and Cast Aluminum and MagnesiumAlloy Products

4.3 Definitions and Symbols. For the purposes of thistest, the following definitions and symbols apply:

A = length of reduced sectionB = length of end sectionC = dimension of grip sectionD = diameterDo = original diameterDf = final diameterE = length of shoulder and filletF = diameter of shoulder G = gage length ID = inner diameterOD = outer diameterL = overall lengthP = loadR = radius of fillet T = specimen thicknesst = thickness of test weldmentW = specimen width

2 ASME standards are published by the American Society ofMechanical Engineers, 345 East 47th Street, New York, NY10017.3 ASTM standards are published by the American Society forTesting and Materials, 100 Barr Harbor Drive, West Consho-hocken, PA 19428-2959.

π = ratio of the circumference of a circle to itsdiameter having a value to five decimal placesof 3.14159

4.4 Summary of Method. Tension testing of weldedjoints is done by means of a calibrated testing machineand devices following the procedures described in 4.8.

4.5 Significance. Tension tests provide information onthe load bearing capacities, joint design, and ductility ofwelded joints.

4.5.1 The data obtained from tension tests mayinclude:

(1) Ultimate tensile strength,

(2) Yield strength,

(3) Yield point if it occurs,

(4) Percent elongation,

(5) Percent reduction of area,

(6) Stress-strain diagram, and

(7) Location and mode of fracture.

4.5.2 Tension tests provide quantitative data that canbe compared and analyzed for use in the design andanalysis of welded structures. Fracture surfaces may alsoprovide information on the presence and effects of dis-continuities such as incomplete fusion, incomplete jointpenetration, porosity, inclusions, and cracking.

4.6 Apparatus. The test shall be performed on a tensiletesting machine in conformance with the requirements ofASTM E 8, Standard Test Methods for Tension Testingof Metallic Materials. The machine shall be calibrated inaccordance with ASTM E 4, Standard Practices forForce Verification of Testing Machines.

4.7 Specimens

4.7.1 Test specimen type shall be specified by theapplicable code, specification, or fabrication document.It is recommended that test specimens that provide thelargest cross-sectional area be tested within the capabili-ties of available test equipment.

4.7.2 Unless otherwise stated, specimens shall be ten-sile tested in the as-received condition.

4.7.3 Round Tension Test Specimens. The specimenhaving the largest diameter of those shown in Figure 4.1,that can be machined from the material shall be tested.

4.7.3.1 Round All-Weld-Metal Specimen. Theall-weld metal tension specimen is used for evaluation ofthe deposited weld metal ultimate tensile strength, yieldstrength, elongation, and reduction in area. When basemetal dilution must be minimized for the specimen to be



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representative of weld metal, the groove faces may bebuttered with the same filler materials to be used in theweld joint or alternatively the root opening may beincreased by l/4 in (6 mm). The reduced section of thetension specimens between the gage marks shall belocated so that no buttering is included. It is recom-mended that the surface of the reduced section of thespecimen be at least l/8 in (3 mm) from the fusion linealong the bevel faces (see Figure 4.1).

4.7.3.2 Round Transverse Weld Specimen. Thetransverse weld specimen is used together with the basemetal or all weld metal tension tests to evaluate joint effi-ciency. Only the ultimate tensile strength is normallydetermined for specimens taken transverse to the center-line of the weld. In the event of use of a set of roundtransverse tensile specimens at various locations in thethickness of the weld specimen, when no other govern-ing specification indicates otherwise, the results of theset of round transverse tensile specimens shall be aver-aged to approximate the tensile properties of the fullthickness joint.

4.7.4 Rectangular Tension Test Specimen. The ten-sion specimens for welded butt joints other than pipe ortubing shall be either transverse weld tension specimensor longitudinal weld tension specimens that comply withFigure 4.2 or 4.3. When thickness of the test weldment isbeyond the capacity of the available test equipment, theweld shall be divided through its thickness into as manyspecimens as required to cover the full weld thicknessand still maintain the specimen size within the test equip-ment capacity. Unless otherwise specified, the results ofthe partial thickness specimens shall be averaged todetermine the properties of the full thickness joint. Onlyultimate tensile strength is normally determined in speci-mens taken transverse to the centerline of the weld.

4.7.5 Tubular Tension Test Specimen. Two types ofspecimens are used in determining the tensile propertiesof welded tubular products.

4.7.5.1 For pipe or tubing larger than 3 in (76 mm)nominal diameter, the reduced rectangular section speci-men may be used. The reduced rectangular section speci-men shall comply with Figure 4.4.

4.7.5.2 The full section specimen may be used totest weld joints in pipe or tubing 3 in (76 mm) or lessnominal diameter and may be used for larger sizes sub-ject to limitations of testing equipment. The full sectionspecimen shall comply with Figure 4.5.

4.7.5.3 Only ultimate tensile strength is normallydetermined in specimens taken transverse to the center-line of the weld.

4.7.6 Preparation. Excessively deep machine cutsthat will cause invalid test data or that leave tears in thesurface of the finished dimensions shall be avoided. Thesurface finish on surfaces requiring machining shall be asspecified in the specimen drawings. Imperfectionspresent within the gage length due to welding shall notbe removed.

4.8 Procedure

4.8.1 The testing procedure for weld specimens shallbe as specified in ASTM E 8/ASTM E 8M, StandardMethods for Tension Testing of Metallic Materials.

4.8.2 Round Tension Specimens. Mechanical prop-erties, namely ultimate tensile strength (UTS), yieldstrength at the specified offset, yield point if it occurs,elongation in a specified gage length, and reduction ofarea are determined for round all-weld-metal tensionspecimens. If a yield point is reported, it shall have beendetermined in accordance with ASTM E 8/ASTM E 8M.The minimum original dimension diameter shall be usedfor all calculations. For round transverse weld tensionspecimens, only ultimate tensile strength is determined,unless otherwise specified.

The ultimate tensile strength is given by:

whereP(Maximum) = maximum load, andDo = original diameter.

The yield strength at specified offset is given by:

whereP(Specified Offset) = load at specified offset, andDo = original diameter.

The yield point is given by:

whereP(yp) = maximum load prior to specific offset, andDo = original diameter.

Maximum LoadOriginal Cross-Sectional Area------------------------------------------------------------------------

P(Maximum)

πDo2

4-----------⎝ ⎠⎛ ⎞

------------------------=

Load at Specified OffsetOriginal Cross-Sectional Area------------------------------------------------------------------------

P(Specified Offset)

πDo2

4-----------⎝ ⎠⎛ ⎞

----------------------------------=

Maximum Load prior to Specific OffsetOriginal Cross-Sectional Area

-----------------------------------------------------------------------------------------------P yp( )

πDo2

4-----------⎝ ⎠⎛ ⎞-----------------=



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4

The percent elongation is given by:

whereGf = final gage length, andGo = original gage length.

The percent reduction of area is given by:

whereDf = final diameter, andDo = original diameter.

4.8.3 Rectangular Tension Tests (Figures 4.2, 4.3,4.4). The ultimate tensile strength calculation for rectan-gular tests is the following:


whereP(Maximum) = maximum load,W = original width, andT = original thickness.

4.8.4 Tubular Tension Tests. The ultimate tensilestrength calculation for reduced section (Figure 4.4) isthe same as shown in 4.8.3. The ultimate tensile strengthcalculation for full section (Figure 4.5) is as follows:


Final gage length – Original gage lengthOriginal gage length

------------------------------------------------------------------------------------------------- 100×

= Gf Go–Go

------------------ 100×

(Original Diameter)2 (Final Diameter)2–

(Original Diameter)2-------------------------------------------------------------------------------------------------- 100×

= Do

2 Df2–

Do2

------------------- 100×

Maximum LoadOriginal Area

--------------------------------------P(Maximum)

W T×------------------------=

whereP(Maximum) = maximum load,OD = original outside diameter, andID = original inside diameter.

4.9 Report. In addition to the requirements of applicabledocuments, the report shall include the following:

(1) Base metal specification,

(2) Filler metal specification,

(3) Welding procedure (process and parameters),

(4) Specimen type,

(5) Joint geometry,

(6) Location of fracture and type of failure (ductile orbrittle),

(7) Calculated ultimate tensile strength, and

(8) Any observation of unusual characteristics of thespecimens or procedure.

In addition, the report for round all-weld-metal specimensshall contain the following:

(1) Yield strength at the specified offset,

(2) Yield point if it occurs,

(3) Percent elongation in the specified gage length, and

(4) Percent reduction of area.

4.10 Commentary. Descriptions of two tensile speci-mens are included in this document, one with a 4:1 ratioof gage length to diameter and one with a 5:1 ratio ofgage length to diameter. Users are cautioned that calcu-lated values of elongation for a given material will differwhen tested using specimens with different ratios of gagelength to specimen diameter.

Maximum LoadOriginal Area

--------------------------------------P(Maximum)

π4--- OD2 ID2–( )×-----------------------------------------=



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5

Notes:1. The reduced section may have a gradual taper from the ends toward the center with the ends not more than 1% larger in diameter

than the center (controlling dimension).2. If desired, the length of the reduced section may be increased to accommodate an extensometer of any convenient gage length.

Reference marks for the measurement of elongation should nevertheless be spaced at the indicated gage length.3. The gage length and fillets shall be as shown but the ends may be of any form to fit the holders of the testing machine in such a way

that the load shall be axial. If the ends are to be held in wedge grips it is desirable to make the length of the grip section great enoughto allow the specimen to extend into the grips a distance equal to 2/3 or more of the length of the grips.

4. The use of specimens smaller than 0.250 in (6 mm) diameter shall be restricted to cases when the material to be tested is ofinsufficient size to obtain larger specimens or when all parties agree to their use for acceptance testing. Smaller specimens requiresuitable equipment and greater skill in both machining and testing.

5. For transverse weld specimens, the weld shall be approximately centered between gage marks.6. Any standard thread is permissible that provides for proper alignment and aids in assuring that the specimen will break within the

reduced section.7. On specimen 5 (see page 6), it is desirable to make the length of the grip section sufficient to allow the specimen to extend into the

grips a distance equal to 2/3 or more of the length of the grips.8. The use of UNF series of threads [3/4 in (19 mm) by 16, 1/2 in (13 mm) by 20, 3/8 in (10 mm) by 24, and 1/8 in (3 mm) by 28] is

recommended for high-strength, brittle materials to avoid fracture in the threaded portion.9. Surface finish within the gage length shall be no rougher than 63 microinches (1.6 micrometers) Ra.

10. On the round specimens in this figure, the gage lengths are equal to 4 times the nominal diameter. In some product specificationsother specimens may be provided for but unless the 4:1 ratio is maintained within dimensional tolerances, the elongation values maynot be comparable with those obtained from the standard test specimen. Note that most metric based codes use a 5:1 ratio of gagelength to diameter.

Figure 4.1—Round Tensile Specimens

Dimensions

Standard Specimen Small-size specimens proportional to standard specimen

Nominal Diameterin (mm)

0.500 (13)in (mm)

0.350 (9)in (mm)

0.250 (6)in (mm)

0.160 (4)in (mm)

0.113 (3)

G. gage length 2.000 ± 0.005(50 ± 0.127)

1.400 ± 0.005(35 ± 0.127)

1.000 ± 0.005(25 ± 0.127)

0.640 ± 0.005(16 ± 0.127)

0.450 ± 0.005(12 ± 0.127)

D. diameter 0.500 ± 0.010(13 ± 0.25)

0.350 ± 0.007(9 ± 0.18)

0.250 ± 0.005(6 ± 0.127)

0.160 ± 0.003(4 ± 0.08)

0.113 ± 0.002(3 ± 0.05)

R. radius of fillet, min. 3/8 (10) 1/4 (6) 3/16 (5) 5/32 (4) 3/32 (2.4)

A. length of reduced section, min. 2-1/4 (60) 1-3/4 (44) 1-1/4 (32) 3/4 (20) 5/8 (15)



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6

Figure 4.1 (Continued)—Round Tensile Specimens

Dimensions

Specimen 1in (mm)

Specimen 2in (mm)

Specimen 3in (mm)

Specimen 4in (mm)

Specimen 5in (mm)

G — gage length 2.000 ± 0.005(50 ± 0.127)

2.000 ± 0.005(50 ± 0.127)

2.000 ± 0.005(50 ± 0.127)

2.000 ± 0.005(50 ± 0.127)

2.000 ± 0.005(50 ± 0.127)

D — diameter (Note 1) 0.500 ± 0.010(13 ± 0.254)

0.500 ± 0.010(13 ± 0.254)

0.500 ± 0.010(13 ± 0.254)

0.500 ± 0.010(13 ± 0.254)

0.500 ± 0.010(13 ± 0.254)

R — radius of fillet, min. 3/8 (10) 3/8 (10) 1/16 (1.6) 3/8 (10) 3/8 (10)

A — length of reduced section(Note 2) 2-1/4 (56) min. 2-1/4 (56) min. 4 (101) approx. 2-1/4 (56) min. 2-1/4 (56) min.

L — over-all length approx. 5 (126) 5-1/2 (139) 5-1/2 (139) 4-3/4 (120) 9-1/2 (241)

B — length of end section 1-3/8 (35) approx. 1 (25) approx. 3/4 (19) approx. 1/2 (13) approx. 3 (76) min.

C — diameter of end section 3/4 (19) 3/4 (19) 23/32 (18) 7/8 (22) 3/4 (19)

E — length of shoulder and fillet section, approx. — 5/8 (16) — 3/4 (19) 5/8 (16)

F — diameter of shoulder — 5/8 (16) — 5/8 (16) 19/32 (15)



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7

Notes:1. Thin base metal being tested tends to tear and break near the shoulder. In such cases, dimension C shall be no greater than 1-1/3

times the width of the reduced section.2. Weld reinforcement and backing strip, if any, shall be removed flush with the surface of the specimen.3. When the thickness, t, of the test weldment is such that it would not provide a specimen within the capacity limitations of the available

test equipment, the specimen shall be parted through its thickness into as many specimens as required.4. The length of reduced sections shall be equal to the width of the widest portion of weld, plus 1/4 in (6 mm) minimum on each side.5. All surfaces in the reduced section shall be no rougher than 125 microinches (3 micrometers) Ra.6. Narrower widths (W and C) may be used when necessary. In such cases, the width of the reduced section should be as large as the

width of the material being tested permits. If the width of the material is less than W, the sides may be parallel throughout the lengthof the specimen.

Figure 4.2—Transverse Rectangular Tension Test Specimen (Plate)



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8

Notes:1. The weld reinforcement and backing, if any, shall be removed, flush with the surface of the specimen.2. The width of the weld may be varied to approximate 1/2 W by selecting an appropriate specimen thickness, T, and its location within

the weld.3. The width, W, may be varied within reason to accommodate the width of the weld if it is not possible to meet the requirements of Note

2.4. The grip sections of the specimen shall be symmetrical with the center line of the reduced section, within 1/8 in (3 mm).5. All surfaces in the reduced section shall be no rougher than 125 microinches (3 micrometers) Ra.6. Narrower widths (W and C) may be used when necessary. In such cases, the width of the reduced section should be as large as the


Figure 4.3—Longitudinal Tension Test Specimens (Plates)

Dimensions

Specimen 1in (mm)

Specimen 2in (mm)

W = width 1 ± 0.05 (25 ± 1.25) 1-1/2 ± 0.125 (38 ± 3)

B = width of weld 1/2 (13) approx. 3/4 (19) approx.

nominal C = width of grip section 1-1/2 (38) 2 (50)



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9

Notes:1. The weld reinforcement and backing, if any, shall be removed flush with the specimen.2. Alternate specimen shall not be used for nominal wall thickness less than 3/8 in (10 mm).3. Only grip sections of the specimen may be flattened.4. In the case of full wall thickness specimens, cross-sectional area may be calculated by multiplying W and t (t = T)5. T is the thickness of the test specimen as provided for in the applicable specification.6. The reduced section shall be parallel within 0.010 in (0.25 mm) and may have a gradual taper in width from the ends toward the

center with the ends not more than 0.010 in (0.25 mm) wider than the center.7. The grip section of the specimen shall be symmetrical with the center line of the reduced section within 1/8 in (3 mm).8. All surfaces in the reduced section shall be no rougher than 125 microinches (3 micrometers) Ra.9. Narrower widths (W and C) may be used when necessary. In such cases, the width of the reduced section should be as large as the


Figure 4.4—Reduced Rectangular Section Tension Specimens for Pipe

SpecimenNo.

Win (mm)

Cin (mm)

Ain (mm)

1 1/2 ± 1/64 (13 ± 0.4) 3/4 (19) approx. 2-1/4 (60) min.

2 3/4 ± 1/32 (20 ± 2.4) 1 (25) approx. 2-1/4 (60) min.4-1/2 (115) min.

3 1 ± 1/16 (25 ± 1.6) 1-1/2 (38) approx. 2-1/4 (60) min.4-1/2 (115) min.

4 1-1/2 ± 1/8 (38 ± 3.2) 2 (50) approx. 2-1/4 (60) min.4-1/2 (115) min.

9 (229) min.



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10

Figure 4.5—Full Section Tension Specimen for Pipe



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AWS B4.0:2007 CLAUSE 5. SHEAR TESTS

11

5. Shear Tests5.1 Scope. This clause covers shear tests of fillet weldsin plate.

5.1.1 The preparation of the test specimens and thetesting procedure shall conform to this standard.

5.1.2 This standard does not specify requirements oracceptance criteria.

5.1.3 This standard is applicable to the followingwhen specified:

(1) Qualification of welding personnel and weldingprocedures;

(2) Information, basis for inspection, and fabricationquality control when acceptance criteria have been estab-lished; and


5.1.4 When this standard is used, the following infor-mation shall be furnished:

(1) Welding process used,

(2) The specified type of test and the number ofspecimens that is required,

(3) Base metal specification/identification and thickness,

(4) Position(s) of welding,

(5) Filler metal specification/identification and diameter,

(6) Report form including type of data and observa-tions to be made, and

(7) Acceptance criteria.


ASTM Documents:

ASTM E 4, Standard Practices for Force Verificationof Testing Machines


5.3 Summary of Method. The shear test places a tensileload on a specimen prepared so that the fillet welds failin shear.

5.4 Significance

5.4.1 Shear tests provide information on the loadbearing capacities and joint efficiencies of welded joints.The data obtained from shear tests may include:

(1) Unit shear load,

(2) Shear strength, and

(3) Location and mode of fracture.

5.4.2 Shear tests provide quantitative data which canbe compared, analyzed, and used in the design and analy-sis of welded structures. Fracture surfaces may also pro-vide information on the presence and effects ofdiscontinuities such as lack of fusion/penetration, poros-ity, inclusions, and cracking. The weld shearing strengthis reported as (1) load per unit length of weld, and (2)shear stress on the throat of the weld.

5.5 Apparatus. The test shall be performed on a tensilemachine in conformance with ASTM E 8, StandardMethods for Tension Testing of Metallic Materials. Themachine shall be calibrated in accordance with ASTME 4, Standard Practices for Force Verification of TestingMachines.

5.6 Specimens

5.6.1 Longitudinal Shear Strength Specimen. Thespecimen shall be welded as shown in Figure 5.1 andinspected visually. The surface contour and size of thefillet welds shall be in accordance with the applicablestandard or other specified acceptance criteria. The spec-imen shall be machined before testing as shown in Figure5.1.

5.6.2 Transverse Shear Strength Specimen. Thespecimen shall be prepared as shown in Figure 5.2 andinspected visually. The surface contour and size of thefillet welds shall be in accordance with the applicablestandard or other specified acceptance criteria. Widerplates may be used to obtain multiple specimens. Whenmultiple specimens are prepared from a single weldedassembly, the results for each individual specimen are tobe reported.

5.6.3 Preparation. The data obtained from a shearstrength specimen may be affected by certain preparationand testing variables. For the transverse specimen, thegap between the lapped plates should be minimized toavoid magnification of stresses at the root of the weldwhich should lower the observed strength of the weld-ment. Nonuniformity of fillet weld contour will affectthe test values. The specimen is also sensitive to anyunderbead cracking or undercut.

5.7 Procedure. Shear strength is derived using formulasfrom Figure 5.3.



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CLAUSE 5. SHEAR TESTS AWS B4.0:2007

12

5.7.1 The length of weld and average leg dimensionof each weld shall be measured and reported. The theo-retical throat is calculated from these dimensions.

5.7.2 The specimen shall be positioned in the testingmachine so that the tensile load is applied parallel to thelongitudinal axis of the specimen.

5.7.3 The specimen shall be loaded in tension until thewelds are sheared.

5.7.4 A test shall be considered invalid if the speci-men fails in the base metal, and an additional test speci-men shall be prepared and tested.

5.7.5 Unit shear load in terms of load per unit lengthof weld is determined by dividing the maximum load bythe total length of weld sheared.

5.7.6 Shear strength in force per unit area acting onthe throat of the fillet weld is determined by dividing theunit shear load by the average theoretical throat dimen-sions of the welds that sheared.

5.7.7 Eccentric loading during testing will make thespecimen more sensitive to certain defects such as welddiscontinuities at the ends of the fillet welds.

5.8 Report. In addition to the requirements of the appli-cable standard or other user specified requirements, thereport should indicate the following:

(1) Specimen identification;

(2) Welding procedure number or identification;

(3) Specimen type (longitudinal or transverse);

(4) Unit shear load;

(5) Shear strength;

(6) Location of fracture;

(7) Actual throat dimensions, if measured and weldlengths; and

(8) Any observation of unusual characteristics of thespecimen, fracture surfaces or procedure.

5.9 Commentary. There are other national and interna-tional test methods whose objectives are to determine theshear properties of welds. These other test methods maynot give the same test results as the test method describedhere.



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AWS B4.0:2007 CLAUSE 5. SHEAR TESTS

13

Notes:1. Slot machined through root of test fillet weld.2. Depth of machined notch shall extend through thickness of lap plate.

Figure 5.1—Longitudinal Fillet Weld Shear Specimen

Dimensions

in (mm) in (mm) in (mm) in (mm)

Size of Weld S 1/8 (3) 1/4 (6) 3/8 (10) 1/2 (12)

Thickness t 3/8 (10) 1/2 (12) 3/4 (19) 1 (25)

Thickness T 3/8 (10) 3/4 (19) 1 (25) 1-1/4 (32)

Width W 3 (75) 3 (75) 3 (75) 3-1/2 (89)



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CLAUSE 5. SHEAR TESTS AWS B4.0:2007

14

Figure 5.2—Transverse Fillet Weld Shear Specimen

τ =

whereP = loadl = total length of fillet weld sheareda = theoretical throat dimensionτ = shear strength of weld

Figure 5.3—Shear Strength Calculation

Pl a×-----------



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AWS B4.0:2007 CLAUSE 6. BEND TESTS

15

6. Bend Tests6.1 Scope

6.1.1 This clause covers the bend testing of filletwelds, groove welds in butt joints and the bend testing ofsurfacing welds. The standard gives the requirements forbend test specimen preparation, test parameters, and test-ing procedures, but does not specify acceptance criteria.

6.1.2 The base materials may be homogenous, clad orotherwise surfaced, except for hardfacing.

6.1.3 This standard is applicable to the following,where specified:

(1) Qualification of materials, welding personnel, andwelding procedures;

(2) Information, specifications of acceptance, manu-facturing quality control; and


6.1.4 When this standard is used, the following infor-mation shall be specified:

(1) The specific location and orientation of thespecimens;

(2) The specific types of tests, for example, face bend,side bend, or root bend and number of specimensrequired;

(3) Bend radius and specimen thickness (T), or per-cent (%) elongation. When not otherwise specified, theelongation is generally determined by the base metal orfiller metal requirement, whichever is lower; and

(4) Postweld thermal or mechanical processing treat-ments, as applicable.


ASME Documents:


ASTM Documents:

ASTM A 370, Standard Test Methods and Definitionsfor Mechanical testing of Steel Products

ASTM E 190, Standard Test Method for Guided BendTest for Ductility of Welds

6.3 Definitions and Symbols. For the purposes of thistest, the following definitions and symbols apply:

A = plunger or mandrel radiusB = die radiuse = elongation of outer surfaceID = inside diameterL = test plate lengthR = radiusS = surfacing weld thicknessT = specimen thicknesst = thickness of test weldmentW = specimen width

6.4 Summary of Method

6.4.1 Specimens are guided in the bending process bya test fixture that employs a mandrel with wraparoundroller or end supports with a plunger.

6.4.2 Maximum strain on the tension surface is con-trolled by the thickness of the specimen and the radius ofthe mandrel or plunger.

6.5 Significance

6.5.1 The ductility of the welded joint, as evidencedby its ability to resist tearing and the presence of defectson the tension surface, is determined in a guided bendtest.

6.5.2 Bend tests of weld cladding are used todetect incomplete fusion, tearing, delamination, macro-discontinuities, and the effect of bead configuration.

6.6 Apparatus

6.6.1 Guided bend specimens may be tested in eitherof two types of fixture. One type is the guided bend fix-ture, which is designed to support and load the specimenin a three point bending mode. The alternate is a wrap-around bend fixture that fixes one end of the specimenand uses a roller to force the specimen to bend around amandrel.

6.6.2 The guided bend fixture shall have the dimen-sions given in Figure 6.1, 6.2, or 6.10.

6.6.3 The wraparound bend fixture shall have thedimensions given in Figure 6.3.

6.6.4 The radius of the plunger, A, shown in Figures6.1 and 6.2 or the mandrel shown in Figure 6.3 shall bespecified or determined from the following equation:

A = T(50/e – 1/2)

whereA = Radius of mandrel or plunger, ±1/16 in

(±1.6 mm);



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CLAUSE 6. BEND TESTS AWS B4.0:2007

16

e = Elongation at outer surface, % ±1%; andT = Specimen thickness, ±1/64 in (±0.40 mm).

6.6.5 The tolerances specified are for machining andto allow use of standard size mandrels and plungers. It isnot the intent of the tolerances to purposely increase theminimum bend radius beyond the calculated value.

6.7 Specimens

6.7.1 Bend test specimens shall be prepared by cuttingthe weld and the base metal to form a specimen rectangu-lar in cross section. For transverse bends, the surfaces cuttransverse to the weld shall be designated as the sides ofthe specimen. For longitudinal specimens, the longitudi-nal surfaces that were cut to form the specimen shall bedesignated as the sides of the specimen and may or maynot contain any weld metal. Of the two remaining full-length surfaces, the surface with the greatest weld facewidth shall be designated as the face while the remainingfull length surface shall be designated as the root. Trans-verse specimens may have the side, face, or root of theweld as the tension surface. Longitudinal specimens mayhave the face or the root of the weld as the tension sur-face of the specimen.

6.7.2 When specimens wider than 1.5 in (38 mm) areto be bent, the mandrel or plunger shall be at least 0.25 in(6 mm) wider than the specimen width.

6.7.3 It is generally recommended that bend testspecimen thickness, T, be 3/8 in ± 1/64 in (10 mm ±0.40 mm) unless otherwise dictated by the material thick-ness, available equipment, or the applicable specification.

6.7.4 Transverse Side Bend. The longitudinal axis ofthe specimen is perpendicular to the weld, and the speci-men is bent so that one of the side surfaces becomes thetension surface of the specimen. The side showing themore significant discontinuities (if any) shall be the ten-sion side. Transverse side bend test specimens shall con-form to Figure 6.4. Transverse side bend specimens areused for plates or pipe that are too thick for face bend orroot bend specimens and are recommended for weldswith narrow fusion zones.

6.7.5 Transverse Face Bend. The longitudinal axisof the specimen is perpendicular to the weld and thespecimen is bent so that the weld face becomes the ten-sion surface of the specimen. Transverse face bend spec-imens shall conform to the requirements of Figure 6.5 forplate and Figure 6.6 for pipe welds.

6.7.6 Transverse Root Bend. The longitudinal axisof the specimen is perpendicular to the weld and thespecimen is bent so that the root surface of the weldbecomes the tension surface of the specimen. Transverse

root bend specimens shall conform to the requirementsof Figure 6.5 for plate and Figure 6.6 for pipe welds.

6.7.7 Longitudinal Face Bend. The longitudinal axisof the specimen is parallel to the weld and the specimenis bent so that the face of the weld becomes the tensionsurface of the specimen. Longitudinal face bend speci-mens shall conform to the requirements of Figure 6.7.

6.7.8 Longitudinal Root Bend. The longitudinal axisof the specimen is parallel to the weld and the specimen isbent so that the root of the weld becomes the tension sur-face of the specimen. Longitudinal root bend test speci-mens shall comply with the requirements of Figure 6.7.

6.7.9 Fillet Weld Root Bend. The fillet weld root-bend test sample shall be welded and prepared as shownin Figure 6.8. The root of the weld shall be the tensionsurface of the specimen. The fillet weld root bend test isan alternate to the fillet weld break test in some codesand specifications (see 9.2).

6.7.10 Surfacing Weld Specimens. The face bendand side bend specimens for surfacing welds shallconform to the requirements of Figure 6.9. The length ofthe transverse bend specimen shall be perpendicular to theweld direction; the length of the longitudinal bend speci-men shall be parallel to the weld direction. The surfaceweld shall be the tension surface of the face bend specimen.

6.7.11 Longitudinal Fillet Weld Specimen. The fil-let weld bend test specimens are prepared by making twofillet welds on a T-joint and machining the specimen asshown in Figure 6.10. The fillet weld shall be the tensionsurface of the specimen.

6.8 Procedure

6.8.1 Unless otherwise specified, the specimen shallbe tested at ambient temperature and deformation shalloccur in a time period no shorter than 15 seconds and nolonger than 2 minutes. If weld and heat-affected zone(HAZ) for transverse specimens are not within thecurved portion of the specimen, the specimen shall bediscarded and another specimen prepared and tested.

6.8.2 Guided Bend Testing

6.8.2.1 Transverse Specimens. The followingprocedure is applicable to guided bend testing of trans-verse specimens:

(1) Place the tension side down on the supporting sur-face of the bend fixture shown in Figures 6.1, 6.2, and6.10. The weld shall be centered in the fixture with thecenterline of the weld within 1/16 in (1.6 mm) of thecenter of the fixture.

(2) Any means may be used for smoothly moving theplunger in relation to the support members of the bendfixture.



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17

(3) For bend fixtures with a bottom open (Figures 6.1and 6.10), apply a sufficient load on the plunger until thespecimen is bottom ejected, or until the radius of theplunger has cleared the radius of the rollers (or shoul-ders). Caution must be used to prevent injury due tothe force of the ejecting specimen.

(4) For bend fixtures with a bottom radius (Figure6.2), the plunger shall force the specimen into the dieuntil the specimen reaches the bottom of the fixture.

6.8.2.2 Longitudinal Specimens. The followingprocedure is applicable to guided bend testing of longitu-dinal specimens:

(1) Center the tension side of the specimen on the sup-porting surfaces of the bend fixture.

(2) Proceed as described in 6.8.2.1(2) and (3) abovefor transverse specimens.

6.8.3 Wraparound Bend Testing. The specimenshall be firmly clamped on one end in the fixture (Figure6.3) so that there is no sliding of the specimen relative tothe mandrel during the bending operation. Alternatively,the specimen may be held stationary against a rotated,nonslipping mandrel of radius A by a stationary compres-sive roller. In this case the specimen is wrapped aroundthe rotating mandrel by draw-bending the specimen frombetween the outer roller and the point where the rotatingmandrel holds the specimen tight against the roller. Fortransverse bend specimens the weld and HAZs shall becentered within the bent portion of the specimen. Testspecimens shall not be removed from the fixture until thepoint where the outer roller contacts the bend specimenand has moved 180° from its starting point along theconvex surface of the bend specimen.

6.8.4 Specimen Inspection. The specimen shall beremoved from the bend fixture and the tension surface ofthe specimen (weld metal and HAZ) visually examinedfor tears or other open defects, and all defect types, quan-tities, sizes, and locations shall be recorded. When frac-ture of the weld specimen occurs prior to completing a180° bend, the angle at which it fractured shall berecorded, if possible. For transverse bend specimens theweld and HAZ shall be centered and completely withinthe bent portion of the specimen after testing.

6.9 Report. In addition to the requirements of applicabledocuments, the report shall include the following:

(1) Materials Identification

(a) Base metal specification

(b) Filler metal specification

(2) Specimen thickness and width

(3) Type of welded joint or surfacing weld

(4) Welding procedure specifications and procedurequalification record numbers (if applicable) includingany supplemental information

(5) Specific tests performed

(6) Bend radius

(7) Test temperature

(8) Number of tests per condition or lot

(9) The following additional information should be in-cluded: number, type, size and location of defects, if any

(10) Bend angle; also identify if specimen fracturesprior to 180°

(11) Any observation of unusual characteristics of thespecimens or procedure

6.10 Commentary

6.10.1 When testing weld specimens containing basemetal and filler metal which have significantly differenttensile and yield strengths, using the test fixtures shownin Figures 6.1 and 6.2, bending will not be uniformly dis-tributed across the weld, HAZ, and base metal. Forexample, if the deposited weld metal has a yield strengthless than that of the base metal, yielding will begin in theweld first, resulting in a true bend radius less than that ofthe plunger. A smaller effective bend radius results in amore severe test of the deposited weld metal.

On the other hand, when the deposited weld metal isstronger than the base metal, bending will begin in theHAZ and adjacent base metal, resulting in bending witha small radius at these points and little, if any, bendingoccurring in the weld metal. The result of this situation isa more severe test of the HAZ or base metal and a lesssevere test of the weld metal.

It is recommended that a wraparound fixture shown inFigure 6.3 be used in these situations or longitudinalbend specimens be used in place of the transverse guidedbend specimens. Testing of welds in dissimilar metals(such as high tensile strength plate to ordinary structuralgrade steels) can produce similar effects because of thetendency for the specimens to shift (slide sideways) dur-ing loading when using the fixtures shown in Figures 6.1and 6.2. The use of a mallet to adjust the specimen in thefixture after the specimen has begun bending is discour-aged as it may result in rapid bending and undue failure.

6.10.2 For welds and materials with elongationexceeding 20%, bend testing at 20% elongation is nor-mally considered sufficient. This takes into considerationthe complexity of the welded joint and common require-ments for weld strength. However, when elongationgreater than 20% is required for serviceability of thejoint, the contracting parties must specify the minimumacceptable elongation for the bend test.



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18

Notes:1. Either hardened and greased shoulders or hardened rollers free to rotate shall be used.2. The shoulder or rollers shall have a minimum bearing length of 2 in (50 mm) for placement of the specimen.3. The shoulders or rollers shall be high enough above the bottom of the fixture so that the specimen will clear the shoulders or rollers

when the plunger is in the low position.4. The plunger shall be fitted with an appropriate base and provision for attachment to the testing machine and shall be designed to

minimize deflection or misalignment.5. The shoulder or roller supports may be made adjustable in the horizontal direction so that specimens of various thickness may be

tested in the same bend fixture.6. The shoulder or roller supports shall be fitted to a base designed to maintain the shoulders or rollers centered and aligned with

respect to the plunger, and minimize deflection or misalignment.7. The maximum plunger radius, A, shall be as specified or as determined from the formula in 6.6.4.

Figure 6.1—Typical Bottom Ejecting Guided Bend Test Fixture



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19

Notes:1. Tapped hole of appropriate size, or other suitable means for attaching plunger to testing machine.2. Either hardened and greased shoulders or hardened rollers free to rotate shall be used in die.3. The plunger and its base shall be designed to minimize deflection and misalignment.4. The plunger shall force the specimen into the die until the specimen becomes U-shaped. The weld and heat-affected zones shall be

centered and completely within the bent portion of the specimen after testing.5. For a given specimen thickness, T, the maximum plunger radius, A, shall be as specified or as determined from the formula in 6.6.4.

For example, fixture dimensions for 20% elongation and a specimen thickness, T, of 3/8 in (10 mm) shall be plunger radius, A, equalto 3/4 in (19 mm) and die radius, B, equal to 1-3/16 in (32 mm).

6. Weld sizes indicated are recommendations. The actual fillet weld size is the responsibility of the user to ensure rigidity and designadequacy.

Figure 6.2—Typical Bottom Guided Bend Test Fixture

Fixture Dimensions for 20% Elongation of Weld

Specimen Thickness, Tin (mm)

Plunger Radius, Ain (mm)

Die Radius, Bin (mm)

3/8 (10) 3/4 (19) 1-3/16 (32)

T 2T A + T + 1/16 (1.6)



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20

Notes:1. Radius A shall be as specified, or as determined from the formula in 6.6.4. Dimensions not shown are the option of the designer,

except that the minimum width of the components shall be 2 in (50 mm).2. It is essential to have adequate rigidity so that the bend fixture will not deflect during testing. The specimen shall be firmly clamped on

one end so that it does not slide during the bending operation.3. Test specimens shall be removed from the bend fixture when the roller has traversed 180° from the starting point.

Figure 6.3—Typical Wraparound Guided Bend Test Fixture



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21

Notes:1. If the thickness, t, of a single-groove weld joint exceeds 1-1/2 in (38 mm), the specimen may be cut into approximately equal strips

between 3/4 in (19 mm) and 1-1/2 in (38 mm) wide. Each strip shall be tested by bending to the same radius as specified or asdetermined by the formula in 6.6.4.

2. If the plate thickness, t, of a double-groove weld joint exceeds 1-1/2 in (38 mm), the specimen may be cut into multiple strips so thatthe root of the weld is centered in one of the strips as shown. Whenever possible it is recommended that the specimen thickness, T,be approximately 3/8 in (10 mm) with each specimen having a width exceeding its thickness. These strips shall be bent to the sameradius as specified or as determined by the formula in 6.6.4.

3. The weld reinforcement and backing, if any, shall be mechanically removed flush with the specimen surface. For performancequalification, if sufficient material is available, acceptable undercut should be removed while maintaining specimen dimensions.

4. The diameter of the test plunger should be equal to or exceed the width of the remaining weld face width in order to test the weld HAZ andbase metal. If this requirement cannot be met, a greater thickness, T, may be chosen in accordance with the formula in 6.6.4.

5. All longitudinal surfaces shall be no rougher than 125 microinches (3 micrometers) Ra. It is recommended that the lay of the surfaceroughness be oriented parallel to the longitudinal axis of the specimen.

Figure 6.4—Transverse Side Bend Specimens (Plate)



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22

Notes:1. The specimen edges may be thermally cut but, in this case, at least 1/8 in (3 mm) of material shall be mechanically removed from the

thermally cut surface.2. For clad metals having an elongation requirement of at least 25%, the specimen thickness, T, may be reduced when using a fixed

bend-radius testing bend fixture. The specimen thickness shall be determined by the formula in 6.6.4.3. If the weld joins base metals of different thicknesses, the specimen should be reduced to a constant thickness based on the thinner

base metal.4. Unless otherwise specified, the weld reinforcement and backing, if any, shall be mechanically removed flush with the specimen

surface. For performance qualification, if sufficient material is available, acceptable undercut should be removed while maintainingspecimen dimensions.

5. The diameter of the test plunger should be equal to or exceed the width of the remaining weld face. If this requirement cannot be met,a greater thickness, T, may be chosen in accordance with the formula in 6.6.4.

6. All longitudinal surfaces shall be no rougher than 125 microinches (3 micrometers) Ra. It is recommended that the lay of the surfaceroughness be parallel to the longitudinal axis of the specimen.

Figure 6.5—Transverse Face Bend and Root Bend Specimen (Plate)



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23

Notes:1. The specimen edges may be thermally cut but, in this case, at least 1/8 in (3 mm) of material shall be mechanically removed from the

thermally cut surfaces.2. If the weld joins base metals of different thicknesses, the specimen should be reduced to a constant thickness based on the thinner

base metal.3. The specimen width shall be 4T, except that it shall not exceed ID/3 where ID is the inside diameter of the pipe.4. The weld reinforcement and backing, if any, shall be mechanically removed flush with the specimen surface. If the back of the joint

is recessed, this surface of the specimen may be removed to a depth not exceeding the recess. For performance qualification, ifsufficient material is available, acceptable undercut should be removed while maintaining specimen dimensions.

5. The diameter of the test plunger should be equal to or exceed the weld width. If this requirement cannot be met, a greater thickness,T, may be chosen in accordance with the formula in 6.6.4.

6. All longitudinal surfaces shall be no rougher than 125 microinches (3 micrometers) Ra. It is recommended that the lay of the surfaceroughness be oriented parallel to the longitudinal axis of the specimen.

Figure 6.6—Transverse Face Bend and Root Bend Specimens (Pipe)



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24

Notes:1. The specimen edges may be thermally cut, but in this case, at least 1/8 in (3 mm) of material shall be mechanically removed from the

thermally cut surface.2. If the weld joins base metals of different thicknesses, the specimen should be reduced to a constant thickness based on the thinner

base metal.3. Weld reinforcement and backing, if any, shall be mechanically removed flush with the surface of the specimen. For performance

qualification, if sufficient material is available, acceptable undercut should be removed while maintaining specimen dimensions.4. All longitudinal surfaces shall be no rougher than 125 microinches (3 micrometers) Ra. It is recommended that the lay of the surface

roughness be oriented parallel to the axis of the specimen.

Figure 6.7—Longitudinal Face Bend and Root Bend Specimen (Plate)



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25

Notes:1. The backing shall be 3/8 in by 2 in (10 mm by 50 mm) minimum unless the test weld is to be inspected radiographically, in which case

the backing bar shall be 3/8 in by 3 in (10 mm by 76 mm) minimum. The backing bar shall be in intimate contact with the base plate.2. The test plate length L, shall be sufficient for the required number of specimens. Specimens shall be removed mechanically from the

test plate.3. The weld reinforcement and backing bar shall be removed mechanically, flush with the base plate.4. All longitudinal surfaces shall be no rougher than 125 microinches (3 micrometers) Ra. It is recommended that the lay of the surface

roughness be oriented parallel with the longitudinal axis of the specimen.

Figure 6.8—Fillet Weld Root Bend Test Specimen



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26

Notes:1. The dimension, T, is the thickness of the test specimen and shall be 3/8 in (10 mm) unless otherwise specified.2. For the longitudinal bend test, the long axis of the specimen shall be parallel to the welding direction. For the transverse bend test, the

long axis shall be perpendicular to the weld direction length of the test specimen.3. The amount of surfacing weld removed from the face-bend specimen surface shall be the minimum necessary to obtain a smooth

surface. The minimum thickness of surfacing weld after finishing shall be 1/8 in (3 mm).4. All longitudinal surfaces shall be no rougher than 125 microinches (3 micrometers) Ra. It is recommended that the lay of the surface

roughness be oriented with the longitudinal axis of the specimen.

Figure 6.9—Surfacing Weld Face Bend and Side Bend Specimen



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27

Notes:1. Mandrel diameter shown is for a maximum 3/4 in (19 mm) thick specimen.2. Other thicknesses of bottom plate and fillet weld leg size may be utilized, provided the mandrel diameter does not exceed 3 times the

specimen thickness. In these cases, the support clearance should be the mandrel diameter plus twice the specimen thickness plus1/4 in (6 mm).

3. Surface finish of the tension surface shall be no rougher than 125 microinches (3 micrometers) Ra.4. Fillet weld size(s) should be 5/16 in to 1/2 in (8 mm to 13 mm).

Figure 6.10—Longitudinal Guided Fillet Weld Bend Test



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CLAUSE 7. FRACTURE TOUGHNESS TESTS AWS B4.0:2007

28

7. Fracture Toughness Tests7.1 Scope

7.1.1 This clause covers the fracture toughness testingof weldments. Methods include the Charpy V-Notch(Cv), the Dynamic Tear (DT), the Plane-Strain FractureToughness (KIc), Crack Tip Opening Displacement(CTOD), and the Drop Weight Nil-Ductility Tempera-ture (DWNDT) Tests.

7.1.2 When a fracture toughness test is required, thepreparation of the weld, the test specimen, and the testmethods shall conform to this standard.

7.1.3 This standard is applicable to the followingwhen specified:

(1) For qualification of materials, welding procedures,and welding personnel where a specified level of fracturetoughness is required;

(2) For information, specification of acceptance andmanufacturing quality control where a minimum crite-rion for fracture toughness is requested. Detailed discus-sion of the selection of test method and a specifiedminimum value in a specific case is beyond the scope ofthis standard; and


7.1.4 When this standard is used the following infor-mation shall be furnished:

(1) The specific types and number of specimensrequired,

(2) Base metal specifications/identification,

(3) Filler material specification/identification,

(4) The anticipated property values and whether theyare maximum or minimum requirements,

(5) Location and orientation of the specimen and notch,

(6) Joint geometry,

(7) Test temperature, and

(8) Postweld thermal or mechanical treatments.


ASME Documents:


ASTM Documents:

ASTM A 370, Standard Test Methods and Definitionsfor Mechanical Testing of Steel Products

ASTM E 23, Standard Methods for Notched BarImpact Testing of Metallic Materials

ASTM E 208, Standard Method for ConductingDrop-Weight Test to Determine Nil-Ductility TransitionTemperature of Ferritic Steels

ASTM E 399, Standard Test Method for Linear-Elastic Plane-Strain Fracture Toughness Klc of MetallicMaterials

ASTM E 604, Standard Test Method for DynamicTear Testing of Metallic Materials

ASTM E 1290, Standard Test Method for Crack-TipOpening Displacement (CTOD) Fracture ToughnessMeasurement

ASTM E 1820, Standard Test Method for Measure-ment of Fracture Toughness

ASTM E 1823, Standard Terminology Relating toFatigue and Fracture Testing

ASTM E 1921, Standard Method for Determinationof Reference Temperature, To, for Ferritic Steels in theTransition Range.

7.3 Summary of Method

7.3.1 The method selected for fracture toughness test-ing shall be that required in the specification of a mate-rial, fabrication document, or as otherwise specified.

7.3.2 Specimens shall be removed from a weldmentso that the results of the test are representative of thestructural performance of the weld joint.

7.4 Significance

7.4.1 Fracture toughness testing provides a measureof resistance to unstable crack extension (i.e., fractureinitiation), ductile tearing, or both.

7.4.2 The welding process and welding procedurehave a significant effect on the mechanical properties ofa weld joint. If the fracture toughness of a weld jointsample is to be representative of its structural perfor-mance, the same welding process, procedure, and weldcooling rates as a function of distance and thickness mustbe used for the sample and the structure.

7.5 Apparatus

7.5.1 The apparatus for conducting the various frac-ture toughness tests shall be in accordance with the latestedition of the following ASTM Standard Methods:



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AWS B4.0:2007 CLAUSE 7. FRACTURE TOUGHNESS TESTS

29

(1) Charpy V-notch, E 23;

(2) Dynamic Tear, E 604;

(3) Plane-Strain Fracture Toughness, E 399;

(4) Drop-weight Nil-Ductility Transition Temperature,E 208;

(5) J1C, A Measure of Fracture Toughness, E 813; and

(6) Crack-Tip Opening Displacement (CTOD) Frac-ture Toughness, E 1290.

7.6 Specimens

7.6.1 Sufficient information shall be provided to prop-erly locate specimens and weld joint; the orientation ofthe weld joint shall also be identified.

7.6.2 Test specimens shall not contain metal thathas been affected thermally as a result of cutting orpreparation.

7.6.3 Unless otherwise specified, the nominal dimen-sions, orientation and notch location of specimens shall bethat shown in Figures 7.1 through 7.6, respectively. Work-ing drawings are provided in the referenced documents.

7.6.4 Unless otherwise specified, the weld metalwidth to specimen thickness relationship for the compacttension specimen shall be as shown in Figure 7.7. Weldmetal test specimens shall be located in the weld joint asclose to the weld face as possible to provide maximumweld metal area in the test specimens. A valid measure ofthe weld metal fracture toughness requires that the frac-ture surface be entirely within the weld metal. A differ-ent value of the fracture toughness may be obtainedwhen the fracture surface includes the weld metal, heat-affected zone (HAZ), and base metal.

7.6.5 When an evaluation of the base metal or HAZ orboth is required, the location of the notch shall be specified.

7.7 Procedure

7.7.1 Test specimen preparation and test procedurefor measuring the fracture toughness of a weldment shallbe in accordance with the following ASTM standardmethods:

(1) Measurement of Fracture Toughness, E 1820;

(2) Charpy V-notch, E 23, except that values up toand including 100% of the testing machine capacity shallbe accepted and reported as fracture energy if the speci-men breaks. The full machine capacity followed by aplus sign (+), shall be reported if the specimen is not bro-ken. All these results may be used to calculate the aver-age energy absorbed provided the minimum averagerequired for acceptance is within the verified range of themachine;

(3) Dynamic Tear, E 604;

(4) Plane-Strain Fracture Toughness, E 399;

(5) Drop-Weight Nil-Ductility Transition Temperature,E 208;

(6) J1C—A Measure of Fracture Toughness, E 1820;and

(7) Crack-Tip Opening Displacement (CTOD) Frac-ture Toughness, E 1290.

7.8 Report

7.8.1 In addition to the requirements of applicabledocuments, the report shall include the following:

(1) Base metal specification;

(2) Filler metal specification;

(3) Welding procedure (process and parameters);

(4) Joint geometry;

(5) Specimen type;

(6) Specimen location, crack plane orientation, andmachined notch position;

(7) Type of test equipment;

(8) Fracture appearance and location;

(9) Test temperature;

(10) Energy absorbed (if applicable); and


7.8.2 Test data should be recorded on a Test ResultsSheet similar to Figure 7.8.



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NOTE—Dimensional Tolerances shall be as follows:

Notch length to edge 90° ± 2°Adjacent sides shall be at 90° ± 10 minutesCross section dimensions ±0.003 in (0.076 mm)Length of specimen (L) +0, –0.100 in (+0, –2.5 mm)Centering of notch (L/2) ±0.039 in (1 mm)Angle of notch ±1°Radius of notch ±0.001 in (0.025 mm)Notch depth ±0.001 in (0.025 mm)Finish requirements 63 microinches (1.5 micrometers) Ra on notched surface and opposite face;

125 microinches (3 micrometers) Ra on other two surfaces

Figure 7.1—Charpy V-Notch Impact Specimen



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31

Figure 7.2—Dynamic Tear Test Specimen, Anvil Supports, and Striker



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32

Notes:1. Dimensions a, B and W are to be determined in accordance with ASTM E 399.2. Surfaces marked A shall be perpendicular and parallel as applicable to within 0.002W total indicator reading (TIR).3. The intersection of the crack starter tips with the two specimen faces shall be equally distant from the top and bottom edges of the

specimen within 0.005W.4. Integral or attachable knife edges for clip gage attachment to the crack mouth may be used.5. Additional specimen configurations my be found in ASTM E 399.6. The notch should be positioned in the area of the weld to be investigated. The position of the machined notch shall be recorded.

Figure 7.3—Compact Tension Fracture Toughness Specimen



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33

Figure 7.4—Standard Drop Weight Nil-Ductility Temperature Test Specimen

Specimen Type

Dimensionin (mm)

P-1Dimensions

P-2Dimensions

P-3Dimensions

T, thickness 1.0 (25)0 0.75 (19) 0.62 (16)

L, length 14.0 (355) 5.0 (125) 5.0 (125)

W, width 3.5 (90)0 2.0 (50)0 2.0 (50)0

DL, deposit length (approximate) 2.5 (62)0 1.75 (44) 1.75 (44)



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34

Figure 7.5—Orientation of Weld Metal Fracture Toughness Specimensin a Double-Groove Weld Thick Section Weldment

Figure 7.6—Crack Plane Orientation Code forCompact Tension Specimens from Welded Plate



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35

Figure 7. 7—Recommended Ratio of Weld Metal to Specimen Thicknessfor Weld-Metal Fracture Toughness Specimen (Compact Tension Specimen)



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36

DROP WEIGHT TEST RESULTS

To: _____________________________________________________________________________ Date:___________________

Specimen No. _______________________________________________________________________________________________

Code: ______________________________________________________________________________________________________

Type of Steel and Specification:__________________________________________________________________________________

Heat Treatment: ______________________________________________________________________________________________

Orientation/Location: __________________________________________________________________________________________

Specimen Type: ______________________________________________________________________________________________

Test Temperature: ____________________________________________________________________________________________

Results of Test:

Reported by: ________________________________________________________________________________________________

Figure 7.8—Suggested Data Sheet for Drop Weight Test

Specimen Results

1 ____ ______________________

2 ____ ______________________

3 ____ ______________________

4 ____ ______________________



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AWS B4.0:2007 CLAUSE 8. HARDNESS TESTS

37

8. Hardness Tests8.1 Scope

8.1.1 This clause covers the indentation hardness test-ing of welds. Test methods include the Brinell, Rock-well, Vickers, and Knoop hardness tests.

8.1.2 When hardness tests are required, test specimenpreparation and testing procedures shall conform to theapplicable hardness test method standard.

8.1.3 This standard does not specify acceptance criteria.

8.1.4 When this standard is used, the following infor-mation shall be furnished:

(1) The specific type of test and number of specimensrequired,

(2) The specific location and orientation of testspecimens,

(3) The specific locations within a test specimen to betested and number of (indentations) required and surfacepreparation,

(4) Base metal specification/identification, and

(5) Filler metal specification/identification.


ASTM Documents:

(1) ASTM E 3, Methods for Preparation of Metallo-graphic Specimens

(2) ASTM E 10, Standard Test Method for BrinellHardness of Metallic Materials

(3) ASTM E 18, Standard Test Methods for RockwellHardness and Rockwell Superficial Hardness of MetallicMaterials

(4) ASTM E 92, Standard Test Method for VickersHardness of Metallic Materials

(5) ASTM E 110, Standard Test Method for Indenta-tion Hardness of Metallic Materials by Portable HardnessTesters

(6) ASTM E 384, Standard Test Method for Micro-indentation Hardness of Materials

8.3 Summary of Method. A calibrated machine forcesan indentor, of specified geometry and under a predeter-

mined load, into the surface of the test specimen andsome measure of the resultant impression is expressed asa specific measure of hardness.

8.4 Significance. Hardness test provide quantitative datawhich can be compared, analyzed, and used in the designof welding procedures. Hardness tests may also be usedin the analysis of weld failures. The Brinell (E10), Rock-well (E18), and Vickers (E92) tests produce relativelylarge indentations and are used for evaluating the weldjoint and unaffected base metal. The microhardness tests,Knoop and Vickers (E384), which produce relativelysmall indentations, are widely used for hardness mea-surements in cross-sections of weld, heat-affected zones(HAZs), or extremely localized weld areas.

When selecting a hardness test method for use on weldoverlays, the thickness of the weld overlays and the basemetal must be within the thickness limits specified in theapplicable ASTM standard test method for the particularhardness testing technique (for example, ASTM E 18paragraph 6.3).

8.5 Apparatus. The apparatus for conducting the varioushardness tests shall be in accordance with one of the fol-lowing applicable ASTM standard test methods:

(1) Brinell, E 10;

(2) Rockwell, E 18;

(3) Vickers, E 92;

(4) Microhardness (Knoop and Vickers), E 384; or

(5) Portable Hardness, E 110.

8.6 Specimens

8.6.1 All requirements of the applicable ASTM stan-dard test method, except those modified by the followingsections, shall apply.

8.6.2 Brinell, Vickers, and Rockwell hardness testmethods are generally used to evaluate unaffected basemetal and weld metal, unless otherwise specified. Inorder to qualify as a valid weld metal hardness test, theedge of an impression shall be no closer than three timesthe major dimension of an indentation from the edge ofthe weld metal in the prepared specimen.

8.6.3 Vickers and Knoop microhardness test methodsare the recommended test methods for fine-scale traverseacross single or multiple weld regions, unless otherwisespecified.

8.6.4 Hardness test should be performed on surfacesprepared in accordance with the applicable hardness testmethod standard. Weld-metal hardness tests are permit-ted only on weld joint cross sections or local areas of theweld reinforcement prepared before testing.



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CLAUSE 8. HARDNESS TESTS AWS B4.0:2007

38

8.6.5 Applicable precautions described in the ASTME 110 standard test method should be placed on the useof portable hardness test methods.

8.7 Procedure. Test procedures for measuring hardnessin weldments shall be in accordance with the latest edi-tion of the applicable ASTM Standard Test Method aslisted in 8.5.

8.8 Report. In addition to the requirements of the appli-cable documents (see 8.2), the report shall include thefollowing:



(3) Type of welded joint or surfacing weld;


(5) Type of test equipment;

(6) Specimen location and orientation;

(7) Hardness scale (Indenter type and load), whenspecified;

(8) Location of impressions;

(9) Any observation of unusual characteristics of thespecimen or procedure; and

(10) Test results.



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AWS B4.0:2007 CLAUSE 9. BREAK TESTS (NICK AND FILLET WELD)

39

9. Break Tests (Nick and Fillet Weld)

9.1 Nick-Break Test9.1.1 Scope

9.1.1.1 This subclause covers nick-break testing ofwelds in pipe or plate.

9.1.1.2 When a nick-break test is required, the prepa-ration of the test specimens and the testing proceduresshall conform to this standard.

9.1.1.3 This standard does not specify requirements oracceptance criteria.

9.1.1.4 This standard is applicable to the followingwhen specified:

(1) Qualification of materials, welding personnel,and welding procedures;

(2) Information, basis for inspection, and fabricationquality control when acceptance criteria have been estab-lished; and


9.1.1.5 When this standard is used, the followinginformation shall be furnished:

(1) Welding procedure (process and parameters)used,

(2) The specific tests and the number of specimensthat are required,

(3) Base metal specification/identification,

(4) Position of welding,

(5) Filler metal specification/identification (whenused),

(6) Location and orientation of the specimens,

(7) Whether external weld reinforcement is to benotched,

(8) Manner of breaking specimen,

(9) Report form including type of data and observa-tions to be made, and

(10) Acceptance criteria.

9.1.2 Normative References. The following standardscontain provisions which, through reference in this text,constitute mandatory provisions of this test. For undatedreferences, the latest edition of the referenced standardshall apply. For dated references, subsequent amend-ments to, or revisions of, any of these publications do notapply.

AWS Documents:

AWS D10.12, Recommended Practices and Proce-dures for Welding Low Carbon Steel Pipe

API Documents:4

(1) API 1104, Welding of Pipelines and RelatedFacilities

(2) API RP 1107, Recommended Pipe Line Mainte-nance Welding Practices

9.1.3 Summary of Method

9.1.3.1 The specimen is fractured by one of the fol-lowing three methods:

(1) Specimens are broken by supporting the ends andstriking one side in the center with a hammer, or bysupporting one end and striking the other end with ahammer;

(2) Specimens are loaded in tension on a testingmachine until fracture occurs; or

(3) Specimens are broken by supporting one end andapplying load at other end of the specimen.

9.1.4 Significance

9.1.4.1 The nick-break test is used to evaluate theproper technique and welding parameters necessary toobtain sound groove or fillet welded joints in pipe orplate. The nick-break test is also used, on occasion, toverify (by destructive testing) results obtained by non-destructive techniques.

9.1.4.2 Nick-break tests are used to evaluate flash buttwelds, pressure welds, or inertia (friction) welds.

9.1.4.3 No significance is attached to the magnitudeof the load required for fracture.

9.1.5 Apparatus

9.1.5.1 Apparatus shall be capable of firmly support-ing the specimen on one or both ends when fractured byuse of a hammer (see Figures 9.1.1, 9.1.2, and 9.1.3).

9.1.5.2 Tests may also be performed either by loadingin tension or three point bending.

9.1.6 Specimens

9.1.6.1 Specimens from Butt Welds. Nick-breakspecimens shall be prepared by cutting the joint and thebase metal to form a rectangular cross section. The spec-imens may be either machine cut or flame cut. Edgesshall be relatively smooth and parallel and shall be

4 API standards are published by the American Petroleum Insti-tute, 2101 L Street, Northwest, Washington, DC 20037.



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CLAUSE 9. BREAK TESTS (NICK AND FILLET WELD) AWS B4.0:2007

40

notched with a hacksaw or band saw or thin abrasivewheel (disc). Notches are located as shown in Figure9.1.4.

9.1.6.2 Full-Sized Specimens. Small weld assembliesmay be tested in their entirety using the complete assem-bly as the specimen. In those cases, the assembly shall benotched at the weld edges to a depth of approximately1/8 in (3 mm) and across the reinforcement to a depth ofapproximately 1/16 in (1.6 mm) similar to that shown inFigure 9.1.4. These may be modified to suit individualassemblies, but the specimen configuration must bereported.

9.1.6.3 Specimens from Flash Butt Welds. Nick-break specimens shall be prepared by cutting the jointand base metal to form a rectangular cross section. Thespecimens shall be as shown in Figure 9.1.5 and mayeither be machine or flame cut or cut by other suitablemeans.

The sides of the specimen may be macroetched to locatethe bond line. The sides of the specimen shall be notchedalong the bond line with a hacksaw, band saw, thin abra-sive wheel (disk) or by other suitable means. Each notchshall be approximately 1/8 in (3 mm) deep, however, thedepth of the notch shall not exceed 10% of the weldthickness. The weld reinforcement need not be removedprior to notching. If the reinforcement will be removedfor service, but remain for testing, the notch shall extendthrough the thickness of the reinforcement and into theweld to a depth in the weld not exceeding 10% of theweld thickness. If the reinforcement will remain on theweld in service, the depth of the notch from the rein-forcement surface shall not exceed 10% of the weldthickness (see Figure 9.1.5).

9.1.6.4 Specimens from Fillet Welds. There are dif-ferent types of nick-break test specimens for testing filletwelded joints.

(1) Pipe branch connections are tested usingmachine-cut or flame-cut specimens from the crotchareas and 90° from crotch (point) areas as shown in Fig-ure 9.1.6. The specimens should be approximately 2 in(50 mm) wide and 3 in (76 mm) in length and notched asshown in Figure 9.1.6.

(2) Pipe sleeve type connections (Figure 9.1.7) aretested using machine-cut or flame-cut specimens equallyspaced around the circumference. The specimens shouldbe at least 3 in (76 mm) wide and 6 in (152 mm) long andnotched as shown in Figure 9.1.7.

(3) Plate fillet welded joints are tested by machine-cut or flame-cut specimens from a lap joint design shownin Figure 9.1.8. The specimens should be approximately3 in (76 mm) wide and 6 in (152 mm) long and notchedas shown in Figure 9.1.8.

9.1.7 Procedure

9.1.7.1 The specimens shall be broken by supportingthe ends and striking or applying a load to the oppositeside, by supporting one end and striking the other endwith a hammer or by pulling in a tensile machine. Whena hammer is used to fracture the specimen, one side is hittwice and then the specimen is turned 180° and the otherside is hit twice. This procedure is continued until thespecimen is broken.

9.1.7.2 After breaking, the fractured faces (in the as-broken condition) of the specimen shall be examinedvisually for discontinuities, usually, for incomplete jointpenetration, incomplete fusion, porosity, cracks, and slaginclusions. The presence of any of these or otherobserved discontinuities shall be reported. The size,spacing, and number of the observed discontinuitiesshould be reported, if observed. If any of these disconti-nuities exceed the specified limits, this should also bereported.

9.1.8 Report. In addition to reporting the test results asrequired by the applicable documents, the report shallalso include the following:




(4) Testing procedure;

(5) Fracture appearance;

(6) Number, type, size, and location of inclusions ordiscontinuities in the fracture surface; and

(7) Any observation of unusual characteristics of thespecimen or procedure.

9.1.9 Commentary. There may be other AWS and ISOnick-break tests available that evaluate welding tech-nique and parameters in pipe, plate, flash butt, and pres-sure welds and these may be used if required by thespecification or by agreement between the contractingparties.



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Figure 9.1.1—Nick-Break Testing Fixture Made Out of 6 in (152 mm) Pipe



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Figure 9.1.2—Nick-Break Test Using Vise

Figure 9.1.3—Testing of Fillet Weld Specimens



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Figure 9.1.4—Nick-Break Test Specimen



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Figure 9.1.5—Specimen for Flash Butt Welds



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Figure 9.1.6—Specimens for Nick-Break Test of Branch Joint Connections



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Figure 9.1.7—Pipe Sleeve Test Specimen



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Figure 9.1.8—Fillet Welded Plate Specimens



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9.2 Fillet Weld Break Test9.2.1 Scope

9.2.1.1 This subclause covers the fillet weld sound-ness test procedures, test parameters, and methods ofobtaining data and the observations usually required, butdoes not specify the requirements or acceptance criteria.When this standard is used as a portion of a standard ordetail specification, the following information should befurnished:

(1) The specific tests and the number of specimensthat are required,

(2) Specific orientation of specimens within the weldsample,

(3) The type of data required and observations to bemade,

(4) The limiting numerical values, and

(5) The interpretation, if any, of the data andobservations.

9.2.2 Summary of Method. One leg of a T-joint is bentupon the other so as to place the root of the weld in ten-sion. The load is maintained until the legs of the jointcome into contact with each other or the joint fractures.

9.2.3 Significance. The purpose of this test is to deter-mine the soundness of fillet welded joints. This test isqualitative in nature with acceptance determined by theextent and nature of any flaws present.

9.2.4 Definitions and Symbols. Unless otherwise noted,the following designations are used:

S = maximum size single pass fillet to be used inproduction

t = plate thickness

9.2.5 Apparatus. The apparatus used shall be capable offirmly holding the specimen and applying the requiredforce.

9.2.6 Specimens

9.2.6.1 Fillet Weld Break: Procedure Qualifica-tion. The uncoated fillet weld break specimen shall bewelded and prepared for the test shown in Figure 9.2.1.The weld shall meet the as-welded visual inspectionrequirements of the applicable code or standard.

9.2.6.2 Fillet Weld Break: Primer Coated Proce-dure Qualification. The fillet weld break specimen shallbe welded over primer-coated material and prepared fortest as shown in Figure 9.2.2. The weld shall present areasonably uniform appearance and shall meet the visual

inspection requirements of the applicable code orstandard.

9.2.6.3 Fillet Weld Break: Galvanized ProcedureQualification. The fillet weld break specimen shall bewelded over galvanized material and prepared for test asshown in Figure 9.2.3. The weld shall present a reason-ably uniform appearance and shall meet the visualinspection requirements of the applicable code orstandard.

9.2.6.4 Fillet Break: Welder Qualification. The fil-let weld break specimen for welder qualification shall bewelded and prepared as shown in Figure 9.2.4. The weldshall meet the visual requirements of the applicable codeor standard.

9.2.6.5 Fillet Break: Tack Welder Qualification.The uncoated fillet weld break specimen for tack welderperformance qualification shall be welded and preparedfor test as shown in Figure 9.2.5. The weld shall presenta reasonably uniform appearance and shall meet thevisual inspection requirements of the applicable code orstandard.

9.2.7 Procedure. A force as shown in Figure 9.2.6 orother forces causing the root of the weld to be in tensionshall be applied to the specimen. The load shall beincreased until the specimen fractures or bends flat uponitself. If the specimen fractures, the fracture surfacesshall be examined visually to the criteria of the applica-ble standard.

9.2.8 Report. In addition to requirements of the applica-ble documents, the report shall include the following:

(1) Base metal specification and applied coatingspecification;


(3) Fillet weld size;


(5) Specimen type;

(6) Fracture appearance;

(7) Number, type, size, and locations of visible inclu-sions or discontinuities; and


9.2.9 Commentary. There may be other AWS and ISOfillet weld break tests available that evaluate the qualita-tive soundness of fillet welded joints and these may beused if required by the specification or by agreementbetween the contracting parties.



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49

Notes:1. Positions qualified shall be in accordance with applicable code or standard.2. Test assembly may be cut into shorter lengths after welding to facilitate testing.3. Plate thickness, t, shall be maximum used in production or 3/8 in (10 mm), whichever is less.4. S, maximum weld size on single pass production fillet welds; and S, minimum weld size on multipass production fillet welds.

Figure 9.2.1—Fillet Weld Break Specimen for Procedure Qualification

Notes:1. Base plate should be same grade and specification material as that used in production.2. Base plate shall be primer coated to maximum thickness which will be applied in production.3. The first side weld shall be removed by gouging or mechanical means and the second side shall be tested.4. Although entire 36 in (914 mm) length is to be tested, the test assembly may be cut into shorter lengths after welding to facilitate

fracturing for examination.5. Plate thickness, t, shall be maximum used in production or 3/8 in (10 mm), whichever is less.6. S, maximum weld size on single pass production fillet welds; and S, minimum weld size on multipass production fillet welds.

Figure 9.2.2—Fillet Weld Break Specimen for Primer Coated Materials



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50

Notes:1. Plate thickness, t, shall be maximum used in production or 3/8 in (10 mm), whichever is less.2. S, maximum weld size on single pass production fillet welds; and S, minimum weld size on multipass production fillet welds.3. Although entire 36 in (914 mm) length is to be tested, the test assembly may be cut into shorter lengths after welding to facilitate

fracturing for examination.4. Galvanized plating shall be the same grade, specification, and maximum thickness as that used in production.

Figure 9.2.3—Fillet Weld Break Specimen for Galvanized Materials

Notes:1. Stop and restart near center.2. Unless otherwise specified, specimen thickness and dimensions are minimum.3. S, maximum weld size on single pass production fillet welds; and S, minimum weld size on multipass production fillet welds.

Figure 9.2.4—Fillet Weld Break Specimen for Welder Qualification



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51

Figure 9.2.5—Fillet Weld Break Specimen for Tack Welder Qualification

Figure 9.2.6—Method of Testing Fillet Weld Break Specimen



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CLAUSE 10. WELDABILITY TESTING AWS B4.0:2007

52

10. Weldability TestingThe term weldability is the capacity of material to bewelded under the imposed fabrication conditions into aspecific, suitably designed structure and to perform satis-factorily in the intended service. There are many vari-ables in the design, fabrication and erection of realstructures as these affect the metallurgical response towelding. No single test or combination of tests can dupli-cate the conditions of a real structure. Laboratory weld-ability tests can only provide an index to comparedifferent metals, procedures and processes.

Within these limitations, weldability testing can providevaluable data on new alloys, welding procedures andwelding processes. Numerous weldability tests havebeen devised all of which can be classified as either sim-ulated tests or actual welding tests.

The tests included in this clause are the Controlled Ther-mal Severity (CTS) Test, Cruciform Test, Implant Test,Lehigh Restraint Test, Varestraint Test, Oblique Y-Groove Test, Welding Institute of Canada (WIC) Test,Trough Test, and the Gapped Bead On Plate (GBOP)Test. Their applications are summarized below:

Weldability Testing Methods

Weldability Tests Application

Controlled Thermal Severity (CTS) Test Assesses the effect of chemical composition and cooling rate on hardness and hydrogen-assisted cracking susceptibility.

Cruciform Test Assesses hydrogen-assisted cracking in fillet welding applications.

Implant Test Measures susceptibility to hydrogen-assisted cracking in HAZ of weldment.

Lehigh Restraint Test Characterizes the degree of restraint necessary to produce weld metal cracking.

Varestraint Test Assesses hot cracking susceptibility.

Oblique Y-Groove Test Assesses susceptibility to weld and HAZ cracking.

Welding Institute of Canada (WIC) Test Assesses weld and HAZ cracking.

Trough Test Assesses susceptibility to hydrogen-assisted cracking.

Gapped Bead On Plate (GBOP) Test Assesses susceptibility to weld metal cracking.



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AWS B4.0:2007 CLAUSE 10. WELDABILITY TESTING

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10.1 Controlled Thermal Severity (CTS) Test

10.1.1 Scope

10.1.1.1 The Controlled Thermal Severity (CTS) testis used for measuring the susceptibility of weld metaland heat-affected zone (HAZ) to cracking. Cooling rateis controlled through welding heat input, plate thickness,and the number of thermal paths available. The fixture isshown in Figure 10.1.1.

While the primary application is to evaluate base metalcomposition, the test may also be used to evaluate theeffects of welding consumables, heat input, or preheatand postweld heat treatments as well as other processvariables. The test evaluates the effects of HAZ coolingrate rather than external restraint.

10.1.1.2 This test is applicable to the following:

(1) Qualification of materials and welding procedureswhere specific acceptance criteria have been specified,and


10.1.1.3 This test is restricted to base materials thickerthan 1/4 in (6 mm).

10.1.1.4 When this standard is specified, the follow-ing information shall be furnished:

(1) Base metal specification/identification;

(2) Base metal heat treatment;

(3) Base metal thickness and/or the Thermal SeverityNumber(s) (TSN) to be tested;

(4) Base metal rolling direction, if possible;

(5) Filler metal specification/identification and diameter;

(6) Type and flow rate of any shielding gas used;

(7) All welding parameters necessary to define theprocedure and the resulting heat input;

(8) Any preheat, interpass temperature control, orpostweld heat treatment to be used; and

(9) Report form including the type of data and obser-vations to be made.

10.1.2 Normative References. The following standardscontain provisions which, through reference in this text,constitute mandatory provisions of this test. For undatedreferences, the latest edition of the referenced standardshall apply. For dated references, subsequent amendmentsto, or revisions of, any of these publications do not apply.

ASME Documents:



10.1.3.1 The CTS test is based on the theory that HAZcracking will occur independently of external restraint.Cracking is thought to happen when cooling at the startof the austenite to martensite transformation exceeds acritical rate. The test is designed to provide knowndegrees of thermal severity approximating those seen incommon structural joint design and plate thickness.

10.1.3.2 The thermal severity of a welded jointdepends upon the heat input of the weld and the com-bined cross-sectional area of the paths through whichheat can flow away from the joint. Heat flow from a jointin which there is one path through which heat can flow istermed a unithermal flow. Unithermal flow through onesection of 1/4 in (6 mm) plate is assigned a ThermalSeverity Number (TSN) of 1.

10.1.3.3 The test specimen consists of two plates (onesquare and one rectangular) bolted together as shown inFigure 10.1.2. All dimensions except plate thickness arefixed. Two anchor welds are made as shown in the figureto provide additional restraint.

10.1.3.4 Two test fillet welds are made in the flatposition. The specimen is allowed to cool by placing thespecimen in the water bath as shown in Figure 10.1.3.

10.1.3.5 The test welds are sectioned and examinedfor cracks. Hardness measurements may also be made.

10.1.4 Significance

10.1.4.1 This test is used to evaluate weld metal andHAZ susceptibility to cracking under the most commonthermal flow conditions.

10.1.5 Definitions and Symbols

10.1.5.1 Unless otherwise stated the following desig-nations are also used.

tt = the thickness of the top (square) platetb = the thickness of the bottom (rectangular) plate

10.1.5.4 The thermal severity number is a numberused to quantify the thermal severity of the joint tested.The number is determined from the following formula:

TSNtri-thermal = 4(t t + 2tb)

whereTSNtri-thermal = thermal severity number for tri-thermal

heat flow,

t t = thickness of the top (square) plate, andtb = thickness of the bottom (rectangular) plate.



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54

10.1.6 Apparatus

10.1.6.1 A simple fixture is required to hold the speci-men so that the test welds can be made in the flat posi-tion. Contact between the specimen and conductivematerials must be minimized throughout the test.

10.1.6.2 Metallographic equipment is required forpolishing and etching sections of the test weld.

10.1.6.3 Microhardness apparatus is required if hard-ness tests are specified.

10.1.7 Specimens

10.1.7.1 Test specimen components are shown in Fig-ure 10.1.2.

10.1.7.2 The cooling bath arrangement is shown inFigure 10.1.3.

10.1.7.3 Minimum plate thickness is 1/4 in (6 mm).

10.1.7.4 The mating surfaces of the plates are to beground to provide intimate contact between these parts.

10.1.7.5 The surfaces of the top plate on which testwelds are to be deposited are to be machined.

10.1.7.6 Rolling direction shall be identified ifpossible.

10.1.7.7 Plates are bolted together as shown in Figure10.1.2 and anchor welds are deposited. The size of theanchor welds should be as given below:

Plate Thickness in (mm) Weld Size in. (mm)

<5/8 (16)≥5/8 (16)

1/4 (6)01/2 (13)

10.1.8 Procedure

10.1.8.1 Test welds are deposited in the flat positionusing fixturing that minimizes contact between the speci-men and thermally conductive surfaces. Between testwelds, the specimen shall be allowed to cool by placingthe specimen in the water bath as shown in Figure 10.1.3.The test welds are to be single pass fillet welds extendingthe full length of the top plate. Actual voltage, current,and travel speed shall be recorded.

10.1.8.2 Any postweld heat treatment shall be accom-plished immediately after deposition the test welds.

10.1.8.3 The test welds are sectioned as shown in Fig-ure 10.1.4. These are examined metallographically forcracks.

10.1.8.4 Hardness tests may be measured in the weldmetal and the HAZ (optional) as shown in Figure 10.1.5.

10.1.9 Report. An example of a suggested data sheet forCTS test results is shown in Figure 10.1.6.

10.1.10 Commentary. A series of CTS tests may bedesigned to evaluate the relationships between testparameters such as TSN, heat input, filler metal, or pro-cess. Commonly, all test parameters but one are heldconstant. Examples of test series interpretation are:

(1) TSN at which cracking occurs for a given basemetal, heat input, and welding procedure;

(2) The heat input at which cracking occurs for agiven base metal, welding process, and TSN; and

(3) Base metal variable (chemistry, heat treatment,etc.) at which cracking occurs for a given TSN, heatinput, and welding process.



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Figure 10.1.1—Fixture Used to Position CTS Specimen for Welding



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56

Notes:1. Welds are placed on sides opposite cooling bath.2. Mating surfaces shall be no rougher than 125 microinches (3 micrometers) Ra.

Figure 10.1.2—CTS Test Specimen



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57

Notes:1. The specimen end that is immersed in the water cooling bath is always opposite to the end containing the test weld being cooled.2. Water depth (D) should be 2-1/2 in (63 mm).

Figure 10.1.3—Cooling Bath Arrangement for CTS Test



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Figure 10.1.4—Sectioning of CTS Specimen

Figure 10.1.5—Typical Location of Microhardness Impressions



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CTS TEST RESULTS

Company Name _____________________________________________________________ Date _______________________

Job/Test No. ________________________________________________________________ Sheet _________ of __________

Description of Investigation ____________________________________________________________________________________

Base Metal Specification_______________________________ Thickness ___________________________________________

Base Metal Heat Treatment_____________________________ Heat No. ____________________________________________

Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________

Welding Procedure Spec. No.___________________________ Welding Process ______________________________________

Test Weld Restraining Weld

Electrode/Wire Spec. No. ________________________ ________________________

Commercial Designation ________________________ ________________________

Diameter ________________________ ________________________

Baking Treatment ________________________ ________________________

Shielding Gas/Flux ________________________ ________________________

TEST WELD

Gas Flow Rate ______________________________________ Flux Size ____________________________________________

Current ____________________________________________ Preheat Temp.________________________________________

Voltage ____________________________________________ Postweld Heat Treatment _______________________________

Polarity ____________________________________________ Ambient Temp. _______________________________________

Travel Speed ________________________________________ Ambient Humidity _____________________________________

Heat Input __________________________________________ Water Bath Temp. _____________________________________

Hydrogen Determination Method ________________________________________________ Date _______________________

__________________________________________________ Result ______________________________________________

Results:

Remarks __________________________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.1.6—Suggested Data Sheet for CTS Test

Weld/Face/Face No.

Mean LegLength

CrackLength

Result(C or NC)

Hardness, HV

HAZ WM BM



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10.2 Cruciform Test10.2.1 Scope

10.2.1.1 The cruciform test is used to measure thesusceptibility to hydrogen-assisted cracking of steelweldments, primarily focusing on fillet welds. While pri-mary application is to evaluate base-metal composition,the test also may be used to evaluate the effects of weld-ing consumables, welding heat input and preheating,postheating, or both, on cracking susceptibility.

10.2.1.2 This standard is applicable to the following:

(1) Qualification of materials and welding proce-dures where specific acceptance standards have beenspecified;

(2) Information, basis of acceptance, or manufacturingand quality control; and


10.2.1.3 The use of this test is restricted as follows:

(1) The test shall not be used for base metal less than3/8 in (10 mm) thick, and

(2) Close control of the welding parameters is re-quired as the results of this test may be affected more bydifferences in parameters than in cracking susceptibility.

10.2.1.4 The following information shall be furnished:


(2) Base-metal specification/identification and actualchemical composition;

(3) Filler metal specification/identification, size,and any prewelding treatment, e.g., baking time andtemperature;

(4) Appropriate preheating postheating treatmentsused;

(5) Acceptance criteria, if applicable; and

(6) The number of cross sections to be examined.


AWS Documents:

AWS A4.3, Standard Methods for Determination ofthe Diffusible Hydrogen Content of Martensitic, Bainitic,and Ferritic Steel Weld Metal Produced by Arc Welding

10.2.3 Summary of Method. Figures applicable to thistest method are shown in Figures 10.2.1 through 10.2.7.

10.2.3.1 The test specimen consists of three platestack welded at their ends to form a double T-joint (Figure10.2.1). A variation of this test called the slotted cruci-form may also be evaluated. In this variation of the cruci-form test, the attached plate (plate B or C) containslongitudinal and transverse notches that are machined onthe edge of the plate as shown in Figure 10.2.3.

10.2.3.2 A single or multipass fillet weld is depositedin succession in each of the four T-joints. Each test weldis allowed to cool to ambient temperature prior to depos-iting the subsequent weld. After the fourth weld is com-pleted, the specimen is given any specified postweldtreatment.

10.2.3.3 The completed welds are examined visuallyfor any external cracks. The standard cruciform speci-men is sectioned transversely for metallographic exami-nation for hydrogen cracks. The slotted cruciformspecimen is sectioned longitudinally and transversely formetallographic examination for hydrogen cracks asshown in Figure 10.2.2.

10.2.3.4 Some additional longitudinal sectioning willalso be required for portions of the slotted cruciform asdiscussed in 10.2.3.6.

10.2.3.5 The recommended base plate thickness forthe slotted cruciform test specimen is 3/4 in (19 mm).Thicker plate may also be used (depending on the appli-cation being simulated). The two surfaces of the continu-ous plate are ground to bright metal prior to assembly.The mating edges of the attached plates B and C aremachined flat prior to assembly. This is essential toinsure intimate contact and good heat transfer betweenthese surfaces during welding of the assembled speci-men. For the slotted cruciform test, notches (or slots) aremachined on the edge of one of the attached plates asshown in Figure 10.2.3. The assembly is tack weldedtogether prior to the test.

10.2.3.6 Sectioning for the slotted cruciform willinvolve sectioning transverse to the direction of weldingfor the longitudinal notches and parallel to the directionof welding for the transverse notches. Schematic illustra-tions of the sectioning for the longitudinal and transversenotches are given in Figures 10.2.4 and 10.2.5. The cutfor the transverse notch is shown in Figure 10.2.5. Thecut for the longitudinal notch is shown in Figure 10.2.4.

10.2.3.7 For the standard cruciform specimen, sections(Figure 10.2.2) are cut transversely from the test weldments.For the slotted cruciform specimen, sections (Figure 10.2.6)are cut longitudinally and transversely. Use of a water-cooled cut-off wheel is recommended where practical.



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61

10.2.4 Significance. This test is relatively severe fordetecting hydrogen cracks. As a result, the test may bemore sensitive to variations in the welding conditionsthan to any differences in the cracking susceptibility ofthe base metals being examined. Therefore, the weldingconditions must be very closely controlled to avoid anyvariations that may lead to incorrect results. Multiplespecimens are required to help assure reliable measure-ment of the cracking susceptibility.

10.2.5 Apparatus. Evaluation for the presence of hydro-gen cracks requires the use of metallographic equipmentto section and prepare the specimen for examination.

10.2.6 Specimens

10.2.6.1 The test specimen is shown in Figure 10.2.1.The minimum base-plate thickness is 3/8 in (10 mm) Thetwo surfaces of Plate A and the mating edges of Plates Band C are ground smooth prior to assembly. This finish isessential to ensure intimate contact and good heat trans-fer between these surfaces during welding of the assem-bled specimen. The specimen is assembled and securelyclamped. The plates are tack welded, and then the clampsare removed.

10.2.6.2 The suggested dimensions of the specimenplates are as follows:

Plate A:Length 12 in (305 mm)Width 6 in (152 mm)

Plates B and C:Length 12 in (305 mm)Width 3 in (76 mm)

10.2.7 Procedure

10.2.7.1 Test welds are deposited in the sequenceshown in Figure 10.2.1. All welding shall be done in theflat (1F) position using a mechanized process to maintainclose control of the welding parameters. If the shieldedmetal arc process is used, it is recommended that thecovered electrodes be fed into the arc mechanicallyrather than manually to maintain uniform parameters.

10.2.7.2 All test welds are deposited in the samedirection of travel. Each weld is made without any arcinterruptions, and the craters at the ends of the test weldsare filled before the arc is extinguished. The same weld-ing parameters are used for each test weld, and each weldshall be of the same size.

10.2.7.3 In some situations, a multipass test weld maybe desired. The sequence for depositing the individualpasses of multipass weld is indicated in Figure 10.2.1.

10.2.7.4 If weld metal cracking occurs in any of thetest welds, the test shall be discontinued and the locationand extent of cracking noted on the test record sheet.

10.2.7.5 If the welding procedure requires preheating,the specimen shall be preheated before depositing eachtest weld. If postweld heat treatment is required, thistreatment shall be applied to the test weldment immedi-ately after completion of welding and before cooling toambient temperatures unless specifically required by theweld procedure to cool the weldment prior to postweldheat treatment. If no postweld heat treatment is required,the as-welded specimen shall be aged at ambient temper-atures for 48 h.

10.2.7.6 After postweld heat treatment or aging, thetest weldment is sectioned and examined for cracks. Forstandard cruciform specimens, sections (Figure 10.2.2)are cut transversely from the test weldment. For slottedcruciform specimens, sections (Figure 10.2.6) are cut longi-tudinally and transversely. Use of a water-cooled cut-offwheel is recommended where practical. Each sectionshall be identified as to its location in the test weldment.The four quadrants corresponding to the fabricationsequence shall be identified. No section shall be locatedcloser than 1 in (25 mm) from the end of the test weld.

10.2.7.7 One face of each section shall be preparedwith metallographic paper (240 grit or finer), etched andexamined at 50X. The presence and location of anycracks shall be recorded.

10.2.7.8 When the test is used to evaluate susceptibil-ity to hydrogen-assisted cracking, a diffusible hydrogendetermination shall be performed for each welding pro-cess and consumable in accordance with AWS A4.3. Thediffusible hydrogen determination shall be performedunder the same conditions as the test weld.

10.2.8 Report. An example of a data sheet for cruciformtest results is shown on Figure 10.2.7.

10.2.8.1 The test results that shall be reported are thefollowing:

(1) Base metal and filler metal identification andchemical composition,

(2) Base metal (specimen) thickness,

(3) Welding parameters,

(4) Any preheating and/or postweld heat treatment,

(5) Fillet weld size and weld bead size for multipasswelds,

(6) Identification of each section cut from the speci-men and each test weld in the section,

(7) Presence and location of any cracks in each testweld in each section, and

(8) Results of diffusible hydrogen test, if available.

10.2.8.2 Test data should be recorded on a TestResults Sheet similar to Figure 10.2.7.



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Figure 10.2.1—Cruciform Test Assembly



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Figure 10.2.2—Locations of Specimens for Examination of Cracks in Cruciform Test

Figure 10.2.3—Schematic Illustration of the Attached Platein the Slotted Cruciform Specimen



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64

Figure 10.2.4—Sectioning for the Longitudinal Notch

Note: L/2 = Half fillet weld leg length.

Figure 10.2.5—Sectioning for the Transverse Notch



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Figure 10.2.6—Location of Metallographic Specimens forExamination of Cracks in the Slotted Cruciform Test



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CRUCIFORM TEST RESULTS




Base Metal Identification_______________________________ Thickness ___________________________________________


Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________


Electrode/Wire Spec. No. ______________________________ Commercial Name ____________________________________

Diameter ___________________________________________ Baking Treatment _____________________________________

Shielding Gas _______________________________________ Flow Rate ___________________________________________

Shielding Flux _______________________________________ Flux Size ____________________________________________


Voltage ____________________________________________ Interpass Temp._______________________________________

Polarity ____________________________________________ Postweld Heat Treatment _______________________________

Travel Speed ________________________________________ Aging Time __________________________________________

Heat Input __________________________________________ Ambient Temp. _______________________________________

Test Weld Size_______________________________________ Ambient Humidity _____________________________________

Number of Weld Beads ________________________________


__________________________________________________ Result ______________________________________________

Weld Pass Identification:

Results:

Remarks __________________________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.2.7—Suggested Data Sheet for Cruciform Test

Weld/SectionNo.

Result(C or NC)

Crack Location and Length

Weld/SectionNo.

Result(C or NC)

Crack Location and Length



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10.3 Implant Test

10.3.1 Scope

10.3.1.1 The implant test is used to evaluate the sus-ceptibility of low-alloy steels to hydrogen-assisted crack-ing. The test may be used to evaluate the effects on HAZcracking susceptibility of welding consumables, weldingheat input, preheating, postheating, or a combination ofthese parameters.





10.3.1.3 This test is applicable only to HAZ crackingcaused by hydrogen.


(1) Base metal identification and specification;

(2) Implant metal identification and specification;

(3) Filler metal identification, specification, andclassification;

(4) Specific type and number of specimens required;

(5) Anticipated strength property values;

(6) Weld procedure (process and parameters); and

(7) Report form when required.


ASME Documents:


ASTM Documents:

ASTM E 4, Verification of Testing Machines

ASTM E 8, Tension Testing of Metallic Materials

AWS Documents:


10.3.3 Summary of Method. Implant testing of weldedjoints is performed using a threaded rod welded into aclosely fitted hole in the test plate. A tensile load isapplied to the rod after welding. The load is maintaineduntil failure or for 24 h. Failure at low stresses or shorttimes is a qualitative indication of susceptibility tohydrogen-induced cracking.

10.3.4 Significance

10.3.4.1 The implant test provides a measure of resis-tance to hydrogen-assisted cracking (cold cracking) inthe HAZ of a weldment.

10.3.4.2 The implant test may be used to select theappropriate base metal/welding consumable combinationto provide the desired cracking-resistance properties inthe as welded condition.

10.3.5 Apparatus

10.3.5.1 Apparatus for the performance of this testmust provide a means of applying and measuring a ten-sile load on the specimen and a means to record time tofailure. If specified, a means to record acoustical emis-sions during the test shall be provided.

10.3.5.2 The tensile load may be applied by a tensiletesting machine, a hydraulic or mechanical mechanism,or the application of a known dead weight to the speci-men. When direct measurement is used, the instrumentused shall be calibrated in accordance with ASTM E 4.When a dead weight is used, the weight shall be cali-brated in accordance with applicable national standards.

10.3.5.3 CAUTION: A restraining clamp shall beemployed to prevent potentially hazardous elasticrebound of the implant specimen when failure occurs.

10.3.6 Specimens

10.3.6.1 The test specimen consists of a steel rod fit-ted into a clearance hole in the center of a specimenplate, with the top of the rod flush with the top of the sur-face of the specimen plate (see Figure 10.3.1).

10.3.6.2 The rod shall be between 1/4 in (6 mm) and3/8 in (10 mm) in diameter and shall be either threadedor notched. The threaded rod is considered the preferableconfiguration. When threaded, the thread shall be a uni-fied national fine (UNF) Class 1 thread, 9/16 in (14 mm)long, consistent with the diameter of the rod. The circularnotch may be machined in the rod in lieu of the thread.



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68

The notch is located so as to coincide with the coarse-grained HAZ below the weld.

10.3.6.3 The minimum recommended specimen platedimensions are 6 in (152 mm) wide by 8 in (203 mm)long by 9/16 in (14 mm) thick.

10.3.7 Procedure

10.3.7.1 The rod shall be positioned in the clearancehole in the specimen plate so that the top of the rod isflush with the surface of the plate.

10.3.7.2 A weld bead shall be deposited on the top ofthe specimen plate directly over the rod and hole.

10.3.7.3 The completed weldment shall be placed inthe apparatus, and the load shall be applied within threeminutes of the completion of welding. The elapsed timebetween the completion of welding and the applicationof the load shall be recorded.

10.3.7.4 The load shall be maintained until failure orfor a minimum of 24 h. Time to failure may be recordedby any suitable means.

10.3.7.5 Notch tensile stress is equal to the loaddivided by the cross-sectional area of the implant. Thearea is determined by using the root diameter of thethread or notch.

10.3.7.6 The lower critical stress is the highest stressat which no failure occurs.


10.3.8 Report. Test data should be recorded on a TestResults Sheet similar to Figure 10.3.3. In addition to therequirements of applicable documents (see 10.3.2), thereport shall include the following for each specimentested:

(1) Base material specification,

(2) Implant material specification,

(3) Filler material specification/classification,

(4) Welding procedure (process and parameters),

(5) Specimen type (implant and base plate),

(6) Results of loading test:

(a) Load applied,

(b) Elapsed time to application to load,

(c) Lower critical stress (if required),

(d) Notch tensile stress (if required),

(e) Location and time to fracture, and

(f) Acoustical emissions (if required).

(7) Ambient temperature,

(8) Relative humidity,

(9) Any observation of unusual characteristics of thespecimens or procedure, and

(10) Results of diffusible hydrogen test.

10.3.9 Commentary. If a series of tests over an appro-priate stress range is made, the data may be plotted asstress versus time to failure, in order to obtain a curvesimilar to the one shown in Figure 10.3.2. The relativeposition of this curve is a measure of the hydrogen-assisted cracking susceptibility of the tested base metal/welding procedure combination. A number of variationsof this test appear in the literature. The most commonvariation is the thread versus the notch, which are bothpermitted in this standard. Some researchers have cooledthe weldment in water before loading but this practicedoes not seem to be prevalent, and the practice is notcovered in this standard. Unified National Fine (Class 1)thread size is specified in an effort to standardize andfacilitate this test.



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69

Note: Bead on plate weld over specimen.

Figure 10.3.1—Implant Test Specimen and Fixture



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Figure 10.3.2—Typical Data for Implant Test Series



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IMPLANT TEST RESULTS





Test Plate Size ______________________________________

Base Metal Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________

Implant Metal Identification _____________________________ Diameter ____________________________________________

Groove Type ________________________________________ Groove Dimensions____________________________________

Implant Metal Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________

Welding Electrode/Wire Specification ____________________________________________________________________________

Commercial Designation_______________________________ Diameter ____________________________________________

Baking Treatment ____________________________________


Shielding Gas _______________________________________ Gas Flow Rate _______________________________________


Current ____________________________________________ Ambient Temp. _______________________________________

Voltage ____________________________________________ Ambient Humidity _____________________________________

Polarity ____________________________________________

Travel Speed ________________________________________

Heat Input __________________________________________


__________________________________________________ Result ______________________________________________

Results:

Method of Fracture Determination ______________________________________________________________________________

Lower Critical Stress _________________________________________________________________________________________

Notch Tensile Strength _______________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.3.3—Suggested Data Sheet for Implant Test

Specimen No.

Applied Load Time, Weld to Load Application,

secondsFractureLocation

Time to Fracture, hrs:minlb. kg



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10.4 Lehigh Restraint Test10.4.1 Scope

10.4.1.1 The Lehigh restraint test is used to createquantitative data on solidification or hydrogen-assistedcracking susceptibility of deposited weld metal. Thequantitative measure of weld crack susceptibility pro-vided by this test is the degree of restraint required toproduce a weld metal crack.


(1) Investigation of the cracking susceptibility ofbase plate and weld metal materials, and



(1) The test is applicable only to base plate materials,

(2) A large amount of base metal is required,

(3) A series of specimens must be tested to obtain acrack susceptibility index, and

(4) Significant specimen preparation is required.


(1) Weld Procedure (process and parameters),

(2) Base metal specification including actual chemi-cal composition,

(3) Base metal thickness,

(4) Filler metal specification and chemical composi-tion of deposited weld metal,

(5) Report form including specific data to be re-corded and observations to be made, and

(6) Acceptance criteria (if any).


AWS Documents:



10.4.3.1 A test weld is deposited in a machinedgroove in a series of flat plate test specimens. Each spec-

imen of the series is designed to provide a differentamount of restraint to the test weld.

10.4.3.2 Each test weld is examined for the presenceof weld metal cracks after the weld cools to roomtemperature.

10.4.3.3 The maximum amount of restraint that isapplied without the occurrence of weld metal cracking isdeemed the index of crack susceptibility for the particu-lar combination of base metal, filler metal and weldingparameters.

10.4.4 Significance

10.4.4.1 This test is used to examine the susceptibilityof deposited weld metal to solidification or hydrogen-assisted cracking. The important variables that can beinvestigated using this test include the base-metal compo-sition, the filler metal composition, preheating effect,welding heat input, weld-bead size, and shape. The test hasbeen used primarily for investigating the effects of weldand base-metal composition on cracking susceptibility.

10.4.5 Definitions and Symbols. Definitions for sym-bols used in 10.4 are as follows:

I = distance from root of the saw cut slots to thespecimen centerline

2I = level of restraintL = length of saw cut slot

10.4.6 Apparatus. Evaluation for the presence of cracksmay require the use of metallographic equipment to sec-tion the test weld and prepare the section for metallurgi-cal examination.

10.4.7 Specimens

10.4.7.1 The specimen configuration is shown in Fig-ure 10.4.1. The test weld (a single pass) is deposited inthe groove machined along the longitudinal centerline ofan 8 in (203 mm) by 12 in (305 mm) plate of the materialbeing examined. The weld is begun at one end of thegroove and is deposited continuously to the other end ofthe groove.

10.4.7.2 The restraint is provided by the mass of theplate surrounding the groove. The level of restraint iscontrolled by sawing slots along the sides and ends of theplate. So that each specimen of the series will provide adifferent level of restraint, each specimen will have slotsof a different length (L in Figure 10.4.1). All slots alongthe sides of a given specimen will be the same length.The slots on the specimen ends will be shorter than theside slots, but all end slots will be of equal length.

10.4.7.3 The level of restraint is inversely propor-tional to the length of the slots and is expressed numeri-cally as the distance between the ends of the slots (2I in



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73

Figure 10.4.1). Thus, as the restraint is decreased bylonger slots, the cracking index also decreases. The sameeffect could be obtained by using plates of decreasingsize, but by varying the slot length, the cooling rate of thetest weld will remain constant in all specimens of theseries.

10.4.7.4 In typical series of test specimens, the speci-men with the highest restraint will not have any slots.The lengths of the slots of each succeeding specimen ofthe series will be increased 1/4 in (6 mm) or 1/2 in(13 mm) to provide decreasing levels of restraint.

10.4.8 Procedure

10.4.8.1 A series of specimens is welded with eachspecimen providing a different level of restraint to thetest weld, i.e., each specimen will have slots of differinglength. Usually, the first test weld is deposited in thespecimen with the highest level of restraint (no periph-eral slots). If this specimen cracks, another specimen thatprovides less restraint (longer slots) is welded. Sufficientspecimens are welded each with a decreasing restraintlevel until a restraint level is reached at which no weld-metal cracking occurs. This level of restraint (2I) isreported as the cracking index of that particular combina-tion of material compositions, welding parameters, etc.The cracking index is the level of restraint below whichno cracking occurs.

10.4.8.2 Examination for cracking usually can bedone visually as the crack normally appears on the sur-face of the weld as the weld cools. If specified, theabsence of a crack should be verified by using liquidpenetrant or magnetic-particle inspection or by sectioningthe weld, polishing the section surface, and examiningthis surface by low-power magnification. Examinationfor hydrogen cracks should be conducted after aging atambient temperature for 24 h.


10.4.9 Report. Test data should be recorded on a TestResults Sheet similar to Figure 10.4.2.

The test results that shall be reported include:

(1) Base metal and filler metal identification,


(3) Welding parameters,

(4) Any preheating temperature and postweld heattreatment,

(5) Weld-bead size and shape,

(6) Presence and length of any weld-metal cracks ateach level of restraint,

(7) Cracking index,

(8) Method of examination for the presence ofcracks, and

(9) Results of diffusible hydrogen tests, if available.

10.4.10 Commentary. There are other U.S. and ISOtest methods available whose objectives are to evaluatethe susceptibility of weld metal and consumables tocracking. This test method is unique in that it is intendedto develop welding parameters and thermal treatments toestablish the onset of weld metal cracking in medium andhigh strength alloy steel structures and components.



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Figure 10.4.1—Lehigh Restraint Weld-Metal Cracking Test Specimen



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LEHIGH TEST RESULTS






Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________




Shielding Gas _______________________________________ Flow Rate ___________________________________________



Voltage ____________________________________________ Postweld Heat Treatment _______________________________

Polarity ____________________________________________ Ambient Temp. _______________________________________


Heat Input __________________________________________

Weld Bead Size and Shape (flat, concave, or convex) _______________________________________________________________


__________________________________________________ Result ______________________________________________

Results:

Method of Crack Determination ________________________________________________________________________________

Resulting Cracking Index _____________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.4.2—Suggested Data Sheet for Lehigh Test

Specimen No. Restraint Index Result (C or NC) Crack Length



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10.5 Varestraint Test10.5.1 Scope. The varestraint test is used to evaluatebase-metal weldability and determine the influence ofthe welding variables on hot cracking of the base metal.A means is provided for augmenting conventionalshrinkage strains to simulate the large shrinkage strainsfound in highly restrained production weldments.


(1) Qualification of materials and welding procedures,

(2) Manufacturing quality control, and



(1) This test is used for base metal in the thicknessrange of 1/4 in (6 mm) to 1/2 in (13 mm). A variation ofthis test, called the mini-varestraint test, is used for basemetal in the thickness range of 1/8 in (3 mm) to 1/4 in(6 mm);

(2) Specialized equipment for testing (see Figure10.5.1) and specimen examination is required;

(3) Welding usually is done by the mechanized gastungsten arc welding (GTAW) process to minimize vari-ables in the welding parameter and testing results; and

(4) Specimens are tested under laboratory conditions.Shop floor or field examination of specimens may not bepractical.


(1) Weld procedure (process and parameters);

(2) Number of specimens to be tested;

(3) Orientation of specimens relative to the rollingdirection of the base metal, if known;

(4) Base-metal chemical composition;

(5) Base-metal thickness;

(6) Desired weld bead surface geometry (weld beadprofile);

(7) Specimen surface finish;

(8) Value of augmented tangential strain (see 10.5.5.4);

(9) Magnification to be used in examination for cracks;and

(10) The rate of loading of the specimen during thetest (if applicable).


10.5.2.1 The test is conducted by depositing a weld ona cantilevered specimen beginning at one end of thespecimen (Figure 10.5.1). When the weld progressesalong the centerline of the specimen to a predeterminedpoint (A), the specimen is bent to conform to a curveddie (B) as the arc continues to a location (C) near the endof the specimen. A series of decreasing radius dies isused to provide various magnitudes of strain, i.e., aug-mented tangential strain, to the solidifying weld in a cor-responding series of test specimens. The strain thatresults in solidification cracking is an index of the cracksusceptibility of the base metal.

10.5.2.2 After cooling, the surface of the weld isexamined for the presence of cracks. Examination isdone at a magnification of 40X to 80X, and the lengthand location of each crack is noted and recorded. Thespecimen may be sectioned and polished for a moreaccurate determination of the presence of cracks.

10.5.2.3 A smaller scale test, called the mini-varestraint test, is used to study the hot-crack suscepti-bility of expensive base metals or more common basemetals in sheet thicknesses. This test utilizes a smallertest specimen [1 in (25 mm) wide × 6 in (152 mm) long]and correspondingly smaller test equipment. The mini-varestraint test may not be practical for thicker materialsince its testing apparatus may not have the loadingcapacity to bend the thicker material.

10.5.3 Significance. The varestraint test is used for theanalytic investigation of the hot-crack sensitivity of welddeposits, the effect of specific alloying elements on thissensitivity and the basic mechanisms of hot cracking.This test combines a direct correlation with actual fabri-cation behavior, reproducibility of results, an ability todifferentiate between small differences in test and weld-ing variables, and uses relatively small test plates.

10.5.4 Definitions and Symbols. Unless otherwise noted,the following designations are used:

A = point of arc progression at which bending forceis applied

B = a series of decreasing radius die blocksC = location of termination of test welde = augmented tangential strain (%)T = specimen thicknessR = die block radius

10.5.5 Apparatus

10.5.5.1 The equipment required for conducting thevarestraint test clamps one end of the flat specimen andprovides a method for bending the specimen around afixed curved die during welding. This concept is illus-



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77

trated in Figure 10.5.1. Curved dies having differentradius are used while conducting a series of tests. Eachspecimen of the series is bent around a die having asmaller radius than the die used with the previous speci-men. The tests are continued until the die radius is smallenough to cause cracking.

10.5.5.2 Localized bending in the vicinity of the mol-ten weld puddle is avoided by using auxiliary bendingplates to force the test specimen to conform to the diecontour. These plates are clamped into the edges of thespecimen and are bent along with the specimen. Theplates are made from rolled steel; their size is 1/2 in(13 mm) thick by 2 in (50 mm) wide by 12 in (305 mm)long. These auxiliary plates are illustrated in Figure10.5.2. Auxiliary plates used with the mini-varestrainttest are 1/4 in (6 mm) thick.

10.5.5.3 The bending force may be applied eitherhydraulically or pneumatically. The design of the equip-ment and method for bending depends on the individualequipment builder.

10.5.5.4 The augmented tangential strain for givenradius of curvature of the die block can be calculatedfrom the following formula:

wheree = augmented tangential strain (%),T = specimen thickness, andR = die block radius.

The typical range of augmented tangential strain is 0% to4%. The required die radius for a given value of aug-mented tangential strain can be calculated using the sameequation.

10.5.5.5 Die block radii for the mini-varestraint testare calculated in the same manner as for the varestrainttest. The overall size of the mini-varestraint die blockmay be smaller as the test specimen is smaller.

10.5.6 Specimens. The varestraint test specimens arerough sawed and machined to size. The specimen size is2 in (50 mm) wide by 12 in (305 mm) long. The speci-men size thickness is 1/4 in (6 mm) or 1/2 in (13 mm)The mini-varestraint specimen is 1 in (25 mm) wide by6 in (152 mm) long. Typical mini-varestraint specimenthicknesses are in the range of 1/8 in (3 mm) to 1/4 in(6 mm). The specimen surface on which the test weldwill be produced should be machined in the longitudinaldirection to a finish no rougher than 125 microinches(3 micrometers) Ra unless it is desired to simulate a sur-face condition used in service.

e T2R T+( )

---------------------=

10.5.7 Procedure

10.5.7.1 The varestraint specimen is clamped in thetest fixture. Auxiliary bending plates, when needed tofacilitate bending, are clamped in the fixture with thespecimen. The removable die block of the desired radiusis fastened in the position shown in Figure 10.5.1. Thearc is initiated on the centerline of the specimen, approx-imately 2 in (50 mm) from the specimen’s unclampedend. The bending force (F) is suddenly applied as thecenter of the arc passes Point A, which is near the pointof tangency between the curved surface of the die blockand the fixed end of the specimen. The specimen andauxiliary bending plates are bent downward until thespecimen conforms to the radius of curvature of the topsurface of the die block. The rate of arc travel is constantfrom its point of initiation to its point of termination inthe runoff area at location C.

10.5.7.2 The bending load and the shielding gas flow(if used) are maintained for five minutes after termina-tion of the weld pass. The specimen then is removedfrom the fixture for examination.

10.5.7.3 The following test parameters shall bemaintained:

(1) Number of Specimens. A minimum of three speci-mens shall be tested under the same conditions at eachselected or required value of augmented tangential strain.

(2) Specimen Orientation. The specimen shall betaken from the base metal so that the 12 in (305 mm)dimension is parallel to the final direction of rolling ormajor working unless the specimen used is a casting or ifservice conditions in which a different orientation of roll-ing direction are to be simulated.

(3) Weld Geometry. The weld puddle geometry iskept constant when using the maximum crack length cri-terion [see 10.5.8.3(2)] for screening of materials.

10.5.8 Report

10.5.8.1 The as-welded surface near Point A is exam-ined for visual evidence of cracks at a magnification of40X, 60X, or 80X. The locations of any HAZ or fusion-zone cracks are shown schematically in Figure 10.5.3.The length of each crack shall be measured to the nearest0.001 in (0.025 mm) with a low-power microscope (40X,60X, or 80X) containing a calibrated reticle in the eye-piece. The test results that are reported shall include thefollowing:

(1) The base-metal type, composition, thickness, andcondition;

(2) The percent augmented tangential strain;



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78

(3) The total crack length of the three specimenstested under the same conditions that were found on theas-welded surface at the specified magnification (40X,60X, or 80X) and the location of the cracks (weld metalor HAZ);

(4) The maximum crack length of each of the threespecimens tested under the same conditions that werefound on the as-welded surface at the specified magnifi-cation (40X, 60X, or 80X) and the location of the cracks(weld metal or HAZ);


(6) Rate of loading of the specimen during the test (ifavailable).

10.5.8.2 The following criteria can be used to evaluatethe test results:

(1) Cracking Threshold. The cracking threshold isthe minimum augmented tangential strain required tocause cracking in a particular base metal with a given setof welding variables. This criterion provides a quantita-tive method for comparing welding procedures.

(2) Maximum Crack Length. The maximum cracklength that is measured in a given specimen can be usedas a quantitative index for preliminary screening of basemetal, filler metal, or both, at comparable levels ofaugmented tangential strain, provided constant puddlegeometry is maintained. This criterion is useful whensearching for metals with low crack sensitivity.

(3) Total Combined Crack Length. The total com-bined crack length is obtained by adding the lengths of

cracks found in the weld metal and in the HAZ of eachspecimen. The total combined crack length produced inthe weld metal and HAZ will give the best quantitativeindex of the hot-crack sensitivity of the weld metal andHAZ, respectively, for a given welding procedure. Thiscriterion also may be used to examine the effects ofwelding procedure changes.


10.5.9 Commentary

10.5.9.1 The technology of the varestraint test is un-dergoing further refinement. The test specimen size andgeometry, test apparatus, interpretation of results, andunderstanding of the effect of test variables on crackingsusceptibility are being examined in detail. Twoarticles5, 6 describing these investigations are included inthe Bibliography of this document. The classical aspectsof the varestraint test have been presented herein.

10.5.9.2 The rate of loading can affect test results anduse of certain rates of loading may result in scatter in testresults.

5 Lin, W. “A model for heat-affected zone liquation cracking.”Welding in the World 30 (9/10): 236–242, 1992.6 Lin, W., Lippold, J. C., and Baeslack III, W.A. “An evalua-tion of heat-affected zone liquation cracking susceptibility, PartI: Development of a method for quantification.” Welding Journal72(4): 135-s–153-s, 1993.



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Figure 10.5.1—Varestraint Test Fixture and Specimen



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Figure 10.5.2—Auxiliary Bending Plates

TOP SURFACE OF TEST WELD SHOWING LOCATION OF ARC, WELD PUDDLE, SOLID-LIQUID INTERFACE ATINSTANT OF APPLICATION OF BENDING FORCE AND WELD METAL AND HEAT-AFFECTED ZONE HOT CRACKS.

Figure 10.5.3—Typical Indications on Top Surface of Test Weld



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VARESTRAINT TEST RESULTS




Base Metal Identification:

Identification ________________________________________ Heat No. ____________________________________________

Width and Thickness__________________________________ Heat Treatment _______________________________________

Metallurgical Condition _______________________________________________________________________________________

Surface Condition ___________________________________________________________________________________________

Rolling Direction _____________________________________

Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________

Filler Metal:

Identification ________________________________________ Diameter ____________________________________________

Feed Rate __________________________________________

Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________

Welding Process _____________________________________ Electrode Type _______________________________________

Electrode Diameter ___________________________________ Shielding Gas ________________________________________

Shielding Gas Flow Rate_______________________________ Shielding Gas Dew Point________________________________

Current ____________________________________________ Polarity _____________________________________________

Arc Voltage _________________________________________ Arc Length___________________________________________

Travel Speed ________________________________________ Heat Input ___________________________________________

Ambient Temp. ______________________________________ Ambient Humidity _____________________________________

Results:

Cracking Threshold __________________________________________________________________________________________

Maximum Crack Length ______________________________________________________________________________________

Total Combined Crack Length__________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.5.4—Suggested Data Sheet for Varestraint Test

SpecimenNo.

DieRadius

TangentStrain

CrackLocation

Numberof Cracks

Length of Each Crack



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10.6 Oblique Y-Groove Test10.6.1 Scope

10.6.1.1 The oblique Y-groove test (Tekken test) is asingle-pass, restrained groove weld test used to evaluatesusceptibility to hydrogen and weld metal solidificationcracking of steel weldments.

10.6.1.2 This standard is applicable to the following,when specified:

(1) Qualification of materials and welding procedures;

(2) Information, basis for a acceptance, and manufac-turing quality control; and



(1) Base-metal thickness limited to 1/2 in (13 mm) orgreater, and

(2) Test results are applicable only to the base-material thickness tested.



(2) Base-metal identification: specification, heat num-ber, mill test chemical composition, and heat treatment;

(3) Base-metal thickness;

(4) Filler metal identification, specification, anddiameter;

(5) Filler metal preweld conditioning (e.g., baking);

(6) Weld preheat temperature;

(7) Maximum interpass temperature; and

(8) Acceptance criteria (if any).


AWS Documents:



10.6.3.1 The test is performed using a set of three flatplate test assemblies welded under identical conditions.Welds are deposited on each side of the test area to pro-vide restraint. A single test weld is deposited in therestrained, machined groove of each assembly.

10.6.3.2 The combination of welding amperage, volt-age, and travel speed shall be such that the specified heatinput range is obtained.

10.6.3.3 Each test weld is examined for the presenceof hydrogen-assisted cracks, not less than 72 h afterdepositing the test weld. Test welds are sectioned asrequired for internal examination.

10.6.3.4 Testing is usually conducted using severaltested sets welded identically over a range of preheattemperatures so that 100% cracking occurs at the lowesttemperature test and 0% cracking occurs at the highesttemperature tested. Resulting data is useful as a compar-ative measure of the susceptibility of the material tocracking.

10.6.4 Significance. This test is used as a comparativemeasure to assess the susceptibility to hydrogen andweld metal solidification cracking of steel weldments.

10.6.5 Apparatus

10.6.5.1 A simple fixture is used to hold the test platesso the restraining welds can be deposited. Water-cooledmechanical means are used to section completed testassemblies for internal examination for the presence ofcracks. Metallographic equipment is required for polish-ing, etching, and examining specimens.

10.6.6 Specimens

10.6.6.1 Test assembly configuration is shown in Fig-ure 10.6.1. All weld joint surfaces shall be machined to125 microinches (3 micrometers) Ra minimum. When itis possible to identify the rolling direction of the materialbeing tested, the parts should be cut and assembled withthe rolling direction perpendicular to the weld groove,unless otherwise specified.

10.6.6.2 The test assembly is fabricated by depositingwelds on each end of the weld groove to provide the nec-essary restraint, as shown in Figure 10.6.1, Section A–A.Low-hydrogen-type mild steel filler metal is normallyused. Welds shall be deposited by a suitable welding pro-cess, using a deep penetrating arc and a weave-beadtechnique to fill the joints with a minimum number ofweld beads. Care shall be taken to minimize angular dis-tortion during welding. Weld reinforcement should beapproximately 1/16 in (1.6 mm). Maximum interpasstemperature should be in accordance with steel manufac-



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83

turers recommendations as applicable to the steel typebeing joined.

10.6.6.3 Each test assembly shall be dimensionallyinspected after cooling to ensure the proper configurationas shown in Figure 10.6.1, Section B–B. The groove rootopening dimension shall be within tolerance.

10.6.6.4 Fabricate a minimum of three test assembliesper set.

10.6.7 Procedure

10.6.7.1 All welding shall be performed in the flatposition (1G).

10.6.7.2 Test assemblies shall be uniformly heated inan oven, to a temperature slightly higher than the desiredpreheat temperature. The test assembly is removed fromthe oven and the surface temperature near the joint prep-aration shall be monitored. Welding shall begin when thedesired preheat temperature is reached.

10.6.7.3 The single-pass test weld shall be depositedas shown in Figure 10.6.2. Welding techniques whichpromote good fusion and crater fill shall be employed.Following welding, the assembly shall be allowed tocool in still air. It shall be left at ambient temperature forminimum period of 48 h before examination for cracks.

10.6.7.4 The test weld area shall be examined for sur-face cracks. If surface cracks are visible, no furtherexamination is required. If cracking is not visible, theweld shall be sectioned and examined microscopically.

10.6.7.5 When sectioning is required, the test weldshould be sectioned at the one-fourth, one-half, andthree-fourth length positions. Water-cooled mechanicalmeans shall be used to section the test welds. Assembliesshall be securely clamped in such a manner that the cut-ting process does not contribute to weld root cracking.Sectioned specimens shall be polished, etched and exam-ined at 20X for cracks.


10.6.8 Report

10.6.8.1 The test results that typically are reportedinclude:

(1) Test number;

(2) Welding procedure specification and procedurequalification record numbers (if applicable);

(3) Base metal identification;

(4) Base metal thickness;

(5) Filler metal identification;

(6) Filler metal diameter;

(7) Shielding gas identification;

(8) All welding parameters necessary to completelydefine the procedure and heat input;

(9) Weld preheat temperature;

(10) Ambient temperature and relative humidity attime of welding;

(11) Maximum interpass temperature allowed duringwelding of restraining welds (if applicable);

(12) Any observation of unusual characteristics of thetest specimen, weld profile, section surface, or proce-dure; and

(13) Results of diffusible hydrogen tests.




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Notes:1. Base metal outer edges may be thermally cut (not required to be machined).2. Joint groove preparation shall be made by machine cutting. Surfaces shall be no rougher than 125 microinches (3 micrometers) Ra. It

is recommended that the lay of the surface roughness be oriented parallel with the longitudinal axis of the specimen.3. Dimension shall be 1/8 in (3 mm) prior to depositing restraining welds.4. Final dimension shall be 0.079 ± 0.008 in (2 mm ± 0.2 mm) after restraining welds are deposited. However, contraction caused during

anchor welding must be considered prior to machining and assembly; typically approximately 0.012 in (0.3 mm) shrinkage.

Figure 10.6.1—Oblique Y-Groove Test Assembly



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Figure 10.6.2—Oblique Y-Groove Test Weld Configuration



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Figure 10.6.2 (Continued)—Oblique Y-Groove Test Weld Configuration



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OBLIQUE Y-GROOVE TEST RESULTS




Material Identification _________________________________________________________

Material Thickness ___________________________________________________________ Rolling Direction Indicated Y/N

Material Heat Treatment ______________________________________________________________________________________

Applicable Welding Procedure No. _______________________________________________

Welding Details ______________________________________________________________ Process_____________________

Date of Welding______________________________________________________ Time Lapse—Welding to Testing (hrs) _____

No. of Test Assemblies Inspected ________________________ Total % Cracking ______________________________________

Remarks __________________________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.6.3—Suggested Data Sheet for Oblique Y-Groove Test

Parameters Test Weld Parameters Anchor Weld Test Weld

Electrode/Wire Dia. Welding Consumable ID

Amperage Specification

Voltage Classification

Polarity Baking Treatment

Travel Speed Shielding Gas Type, Medium

Preheat Temperature Shielding Gas Dew Point

Heat Input Max. Interpass Temp.

Humidity (RH) Measuring Method

Ambient Temp.

Hydrogen Determination Method Date Result

EXAMINATION

Surface Section

Assembly No. Inspection Method Results (C or NC) Inspection Method Results (C or NC)



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10.7 Welding Institute of Canada (WIC) Test

10.7.1 Scope

10.7.1.1 The Welding Institute of Canada (WIC)cracking test was originally introduced as a general highrestraint test for low carbon steel weldments. While theprimary application is to evaluate weld metal, the testalso may be used to evaluate the effects of welding heatinput, base plate composition, and welding preheat, onweld metal and heat-affected zone (HAZ) cracking sus-ceptibility.






(1) The test shall be used for 3/4 in to 1 in (19 mm to25 mm) thick base metal; and

(2) Close control of all welding conditions isrequired. The results of this test may be strongly affectedmore by changes in welding conditions.

10.7.1.4 The following information shall befurnished:


(2) Base metal specification/identification, thickness,and actual chemical composition, if available;

(3) State of heat treatment;

(4) Base metal rolling direction;

(5) Filler metal specification/identification, diameter,and any prewelding treatment (e.g., electrode bakingtemperature and time);

(6) Cross-sectional examination procedure;

(7) Acceptance criteria, if applicable; and

(8) Report form including specific data to berecorded and observations to be made.

10.7.2 Normative References. The following standardscontain provisions which, through reference in this text,constitute mandatory provisions of this test. For undatedreferences, the latest edition of the referenced standardshall apply. For dated references, subsequent amend-

ments to, or revisions of, any of these publications do notapply.

ASTM Documents:

ASTM E 3, Methods for Preparation of Metallo-graphic Specimens

AWS Documents:



10.7.3.1 The WIC test specimen is schematicallyillustrated in Figure 10.7.1. The WIC specimen was orig-inally developed in Canada using metric dimensions.The WIC specimen joint design may be either a straightY or oblique Y as shown in Figures 10.7.2 and 10.7.3. Astraight Y joint is used when weld deposit hydrogen-assisted cracking resistance is of principal interest. Anoblique Y is used when the hydrogen-assisted crackingof both the HAZ and weld metal are of interest.

10.7.3.2 The WIC specimen is restrained by filletwelding the specimen on 3 sides to either a tee beam (asshown in Figure 10.7.1) or a thick restraining plate. Thefillet size shall be a minimum of 5/16 in (8 mm). If a fab-ricated tee beam is used it shall be made from a mini-mum of 1 in (25 mm) thick plate. If a simple restrainingplate is used, it shall be a minimum of 2 in (50 mm) thickplate. A run-on/run-off tab shall be used on each speci-men. Each test condition of interest is usually run in trip-licate. Three specimens separated by run-on/run-off tabscan be placed sequentially and welded at the same time.The run-on/run-off tabs are typically half the thickness ofthe test specimen and can be any convenient length andwidth. If possible, the run-on/run-off tabs are made fromthe same material as the WIC specimen.

10.7.3.3 A single pass weld is deposited in the weldjoint. After the welding is completed, the specimen isheld a minimum of 24 h prior to final inspection.

10.7.3.4 The completed welds are examined by mag-netic particle inspection for external cracks. The speci-men may also be sectioned transverse to the direction ofwelding, in the center of the specimen, to detect subsur-face root cracks.

10.7.4 Significance. This test is used to evaluate thecracking susceptibility of the weld metal and HAZ in sit-uations simulating the root pass in a highly restrainedbutt weld. The welding conditions must be very closelycontrolled to avoid variations that may result in inconsis-tent results. Multiple specimens may be required toassure reliable assessment of the cracking susceptibility.



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89

10.7.5 Apparatus. A 2 in (50 mm) thick steel plate or atee beam made from 1 in (25 mm) thick steel plate isused to restrain the WIC specimen. The WIC specimen isfillet welded on 3 sides to either a tee beam (as shown inFigure 10.7.1) or a thick restraining plate. The fillet sizeshall be a minimum of 5/16 in (8 mm). Evaluation for thepresence of hydrogen cracks requires the use of metallo-graphic equipment to section and prepare the specimenfor examination.

10.7.6 Specimens. The test specimen is shown in Figure10.7.1. The recommended base plate thickness is 3/4 in(19 mm) to 1 in (25 mm). The surfaces in and around theweld joint are ground to bright metal prior to assembly.The surfaces between the WIC specimen and therestraining plate shall be ground flat prior to assembly.This is essential to ensure intimate contact and good heattransfer during test weld. The test assembly is filletwelded to a 2 in (50 mm) thick restraining plate or 1 in(25 mm) tee section as shown in Figure 10.7.2 prior tothe test. A minimum 1/2 in (13 mm) long (any convenientwidth) run-on and run-off shall be used for each specimen.

10.7.7 Procedure

10.7.7.1 All welding shall be done in the flat positionunless otherwise specified. A mechanized process maybe used to maintain control of the welding parameters.

10.7.7.2 Each weld is made without any arc interrup-tions in the test region. Weld starts and stops will beplaced on the weld run-on and run-off tabs, and the cra-ters at the ends of the test are to be filled before the arc isextinguished. The same welding parameters are used foreach test weld and each weld should be of the same size.

10.7.7.3 The fabrication sequence is as follows: (1)Establish the desired preheat temperature of interest. (2)If no preheat is used, record ambient temperature of thespecimen. The single pass weld deposit shall employwelding techniques that promote good fusion and craterfill.

10.7.7.4 If the welding procedure requires preheating,the specimen shall be preheated before depositing eachtest weld. If postweld heat treatment is required, thetreatment shall be applied to the test weldment immedi-ately after completion of welding and before cooling toambient temperature unless specifically required by theweld procedure to cool the weldment prior to postweld

heat treatment. If no postweld heat treatment is required,the as-welded specimen shall be held at ambient temper-ature for 24 h prior to final inspection or as specified bythe customer.

10.7.7.5 If weld metal cracking occurs in any of thetest welds, the location and extent of cracking shall benoted on the test record sheet.

10.7.7.6 The test weld shall be examined for surfacecracks using magnetic particle inspection. Examinationof a transverse cross section is recommended, especiallyif the oblique Y-groove is employed. The requirementfor sectioning should be specified in the work contract oras agreed by the customer and vendor.

10.7.7.7 If sectioning is required, macrosections arecut transverse to the direction of welding from the centerof the weldment, preferably by using a water-cooledbandsaw or abrasive cut-off wheel. Each macrosectionshall be identified. The face of the section to be exam-ined is polished, etched, and examined at 50X or greatermagnification. The location and size of any cracks shallbe recorded.

10.7.7.8 A diffusible hydrogen test shall be performedfor each welding process and consumable in accordancewith AWS A4.3. The diffusible hydrogen test should beperformed under the same ambient condition as the WICtest weldment.

10.7.8 Report. The test results that typically are reportedare the following:

(1) Base metal and filler metal identification andchemical composition,


(3) Welding procedures (process and parameters),

(4) Any preheating and/or postweld heat treatment,

(5) Identification of each section cut from the speci-men,

(6) Location and size of any cracks in each test weldin each section,

(7) Results of diffusible hydrogen test, and

(8) Test data should be recorded on a Test RecordSheet similar to Figure 10.7.4.



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Figure 10.7.1—Schematic Illustration of the WIC Test Assembly

Figure 10.7.2—Illustration of the Straight Y Joint Design for the WIC Specimen

Figure 10.7.3—Illustration of the Oblique Y Joint Design for the WIC Specimen



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WIC TEST RESULTS




Material Identification _________________________________________________________

Material Thickness ___________________________________________________________ Rolling Direction Indicated Y/N

Material Heat Treatment ______________________________________________________________________________________

Applicable Welding Procedure No. _______________________________________________

Welding Details ______________________________________________________________ Process_____________________

Date of Welding______________________________________________________ Time Lapse—Welding to Testing (hrs) _____

No. of Test Assemblies Inspected ________________________ Total % Cracking ______________________________________

Remarks __________________________________________________________________________________________________

Remarks __________________________________________________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.7.4—Suggested Data Sheet for WIC Test

Parameters Test Weld Parameters Anchor Weld Test Weld

Electrode/Wire Dia. Welding Consumable ID

Amperage Specification

Voltage Classification

Polarity Baking Treatment

Travel Speed Shielding Gas Type, Medium

Preheat Temperature Shielding Gas Dew Point

Heat Input Max. Interpass Temp.

Humidity (RH) Measuring Method

Ambient Temp.

Hydrogen Determination Method Date Result

EXAMINATION

Surface Section

Assembly No. Inspection Method Results (C or NC) Inspection Method Results (C or NC)



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10.8 Trough Test10.8.1 Scope

10.8.1.1 The trough test is used to evaluate the sus-ceptibility of medium and high strength alloy steel weldmetal and consumables to hydrogen-assisted cracking.The primary focus of this test is to establish thermaltreatments that eliminate time-delayed cracking in thicksection repair welds particularly during shielded-metalarc welding (SMAW).

While the primary application is to evaluate the need ortype of thermal treatments required to eliminate poten-tially damaging hydrogen related weld metal cracking,this test may be used to evaluate the effects of weldingprocedure, welding consumables, welding heat input,interpass temperature, and postheating on cracking sus-ceptibility. For weldments or welding procedures thatmay not need postweld heat treatment, this test may beused to determine the sensitivity to hydrogen embrittle-ment and hydrogen-assisted cracking.






(1) Base metal and welding consumables susceptibleto time delayed hydrogen-assisted cracking,

(2) Short highly restrained repair weld in thick sec-tion alloy steel base metal, and

(3) Close control of the welding parameters is re-quired as the results may be affected more by differencesin parameters than in delayed cracking susceptibility.

10.8.1.4 The following information shall be fur-nished:


(2) Base-metal specification/identification and chem-ical composition;

(3) Filler metal specification/identification, size, and,any preweld treatment, e.g., baking time and temperature;

(4) The type, number, and location of tensile speci-mens to be tested;

(5) Report form when required.


ASTM Documents:

ASTM E 4, Standard Practices for Load Verificationof Testing Machines


AWS Documents:

AWS A4.3, Standard Methods for Determination ofthe Diffusible Hydrogen Content of Martensitic, Bainiticand Ferritic Steel Weld Metal Produced by Arc Welding


10.8.3.1 The conditions that promote hydrogen-related delayed weld metal cracking can usually be foundduring short repair welds in highly restrained weldmentsor base metal. The trough test was developed to definethermal treatments that eliminate delayed weld metalcracking.

10.8.3.2 The trough test specimen is shown in Figure10.8.1. The trough configuration is prepared by air-carbon arc cutting or other suitable methods to achievethe joint design shown in Figure 10.8.1. Subsequentgrinding is used to obtain the required trough dimen-sions, to remove all gouging deposits and provide abright metal trough surface.

10.8.3.3 The test specimen is welded in the flat posi-tion and monitored for up to 30 days or until weld crack-ing occurs. Thermal treatments are applied to various testweldments that result in the elimination of hydrogenrelated delayed weld metal cracking.

10.8.4 Significance

10.8.4.1 The trough weld test is based on the theorythat hydrogen related delayed weld metal crackingand/or reduced tensile ductility can be controlled by thecareful application of appropriate thermal treatments insteel weldments. For example, the SMAW process intro-duces hydrogen into the weld metal through the directtransfer across the arc of moisture contained within theelectrode coating. Moisture transfer from the electrodecoating to the weld metal can be minimized by followingsound welding procedure control such as electrodebaking, limiting electrode exposure through the use ofportable holding containers and periodic sampling ofelectrode coatings to ensure that the percentage of mois-



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93

ture remains below the maximum recommended by theelectrode manufacturer or specification. Despite theseprecautions, hydrogen levels in weld metal can exceedthe safe level at which sound weldments can be fabri-cated. The presence of excessive amounts of dissolvedhydrogen can be observed as time delayed transversecracking of weld metal. As hydrogen levels decrease,weld-metal cracking propensity decreases, however, dif-fusible hydrogen can result in reduced tensile ductility ofthe weld metal.

10.8.4.2 The major characteristics of hydrogenembrittlement are its strain-rate sensitivity, temperaturedependence and susceptibility to delayed fracture.Unlike most embrittlement phenomena, hydrogenembrittlement is enhanced by slow strain rates. For steel,the region of greatest susceptibility to hydrogen embrit-tlement is at approximately room temperature.

10.8.4.3 Hydrogen introduction into the weld metal isnot limited to the SMAW process. Other welding pro-cesses (GMAW, SAW, etc.) may also provide the envi-ronment that promotes the conditions leading tohydrogen-related delayed cracking.

10.8.5 Apparatus

10.8.5.1 A simple fixture is required to hold the speci-men so that the test welds can be deposited in the flatposition. Welding in the flat position minimizes variabil-ity in welder skill and enhances the depositing of satis-factory welds not requiring quality interpretation.

10.8.5.2 Electric strip heaters are required to providethe preweld, intraweld, and postweld heating of the testspecimen. Appropriate temperature control, measuring,and recording instruments may be needed to documentthe thermal treatment applied to the test specimen.

10.8.6 Specimens

10.8.6.1 The specimen and groove configuration isshown in Figure 10.8.1. The specimen may be preparedby thermal cutting.

10.8.6.2 The trough is prepared by air carbon arc cut-ting followed by grinding of the trough surface to brightmetal and required dimensions.

10.8.6.3 The amount of restraint required to producetime-delayed weld metal cracking is provided by themass of the plate surrounding the trough groove.

10.8.6.4 The location of tension test specimens in thetrough weld is shown in Figure 10.8.2. Tension testing isused to evaluate tensile ductility.

10.8.6.5 A series of test specimens is welded witheach specimen subjected to a thermal treatment proce-

dure designed to eliminate hydrogen related delayedweld metal cracking and/or reduced tensile ductility.

10.8.7 Procedure

10.8.7.1 The test welds are deposited in the trough inthe flat position.

10.8.7.2 The starts and stops of the weld beads arestacked in the trough one on top of the other as indicatedin Figure 10.8.2. This is done in order to evaluate thesusceptibility of these locations to high levels of hydro-gen and possible defect sites. All starts and stops shall belightly ground between passes.

10.8.7.3 The initial trough specimen is produced bycontinuous welding and minimum preheat and interpasstemperature in order to simulate and effect time delayedweld metal cracking. Appropriate preheat, interpass, andpostweld thermal treatments are applied to subsequentspecimens until weld metal cracking is eliminated and/ortensile ductility is recovered. An outline of suggestedthermal treatments is as follows:

(1) Continuous welding with required preheat andinterpass temperature applied; no postweld treatment.Delayed weld cracking and reduced tensile ductilityshould be evident;

(2) Continuous welding of 1/2 in (13 mm) thick lay-ers with required preheat and interpass temperatureapplied; followed by an elevated postweld treatment at400°F (204°C) for 12 h to 16 h; and

(3) Other thermal treatments may be applied provid-ing they result in eliminating weld metal cracking and/orreduced tensile ductility.

10.8.7.4 All trough specimens shall be subjected tomagnetic particle inspection immediately upon comple-tion of welding and daily for periods up to 30 days. Radi-ography may be used to confirm the results of magneticparticle inspection for weld soundness.

10.8.7.5 The location of tension test specimens in thetrough weld is shown in Figure 10.8.2. Tensile testing isused to evaluate the loss of tensile ductility in the weldmetal as a result of hydrogen embrittlement.

10.8.7.6 When the test is used to evaluate hydrogen-cracking susceptibility, a diffusible hydrogen determina-tion shall be performed for each welding process andconsumable in accordance with AWS A4.3. The diffus-ible hydrogen determination shall be performed underthe same conditions as the test weld.

10.8.8 Report. In addition to the requirements of theapplicable documents, the report shall include thefollowing:



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94


(2) Filler metal specification, size, and chemicalcomposition;

(3) Trough test specimen dimensions and thickness;


(5) Shielding gas identification;

(6) Location of weld starts and stops;

(7) Preheat, interpass, and postweld thermal treatmentsused;

(8) Description of thermal treatment found to elimi-nate delayed cracking and/or reduced tensile ductility;

(9) Time delay and description for presence ofcracks;

(10) Method of examination for presence of cracks;

(11) Tension test ductility, if required; and

(12) Results of diffusible hydrogen test, if required.

Test data should be recorded on a Test Results Sheetsimilar to Figure 10.8.3.

10.8.9 Commentary. There are other U.S. and ISO testmethods available whose objectives are to evaluate thesusceptibility of weld metal and consumables to hydro-gen-assisted cracking. This test method is unique in thatit is intended to determine welding parameters and ther-mal treatments to eliminate hydrogen-assisted crackingin repair welds in thick section medium and high strengthalloy steel structures and components.



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Figure 10.8.1—Trough Test Specimen

Figure 10.8.2—Location of Weld Starts, Stops, and Tension Test Specimens (Side View)



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TROUGH TEST RESULTS




Base Metal Identification and Thickness__________________________________________________________________________

Base Metal Heat Treatment_____________________________________________________ Heat No. ____________________

Base Metal Composition:

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________

Weld Metal Composition ______________________________________________________________________________________

C__________ Si __________ Mn ________ P __________ S__________ Cr__________ Mo ________

Ni _________ V __________ Cu_________ Nb _________ Ca_________ B __________ Ti _________

Al _________ N __________ _________ __________ _________ __________ _________

Welding Process Procedure Spec. No.___________________________________________________________________________



Shielding Gas/Flux ___________________________________ Flow Rate/Flux Size ___________________________________

Current ____________________________________________ Ambient Temp. _______________________________________


Current ____________________________________________ Voltage _____________________________________________

Heat Input __________________________________________


Result ____________________________________________________________________________________________________

Results:

Results (cracking free welding and thermal treatment)_______________________________________________________________

Tested By __________________________________________________________________

Signature___________________________________________________________________ Date _______________________

Figure 10.8.3—Suggested Data Sheet for Trough Test

Specimen No. Welding and Thermal Treatmenta Cracking Time Lapse (Days) Red. in Tensile Ductility (Y/N)

a See 10.8.7.3 for suggested welding and thermal treatment (number of weld layers, preheat and interpass temperature, postweldthermal treatment).



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10.9 Gapped Bead On Plate (GBOP) Test

10.9.1 Scope

10.9.1.1 This subclause covers the Gapped Bead OnPlate (GBOP) test for susceptibility of as-welded metalto hydrogen-assisted cracking. The standard gives therequirements for test specimen preparation, test parame-ters and testing procedures, but does not specify therequirements or acceptance criteria.

10.9.1.2 Where specified, this standard is applicableto the following:

(1) Information, specifications of acceptance, manu-facturing quality control; and




(2) The specific criteria used for distinguishingcracked verses not cracked samples. For example, 50%cracked may be used as the distinguishing level of crack-ing to be considered “cracked”; and

(3) The specific test temperature [for example, test-ing may start at 212°F (100°C)].


ASME Documents:


10.9.3 Summary of Method. This test assesses the sus-ceptibility of weld metal to hydrogen-assisted cracking.A preheat temperature at which the weld metal showsacceptable resistance to hydrogen-assisted cracking isdetermined. At low temperatures hydrogen can’t easilyescape, causing a weld metal condition that is susceptibleto cracking. Conversely, at higher preheat temperatures,there is more opportunity for the hydrogen to diffuse out,and susceptibility to hydrogen-assisted cracking is reduced.

10.9.4 Significance. Hydrogen-assisted cracking is amajor cause for concern in weldments. Understanding ofappropriate preheat temperatures to reduce the suscepti-bility of a weldment to such cracking can be beneficial

for both electrode comparison and determination ofappropriate welding procedures.

10.9.5 Apparatus. The apparatus consists of 2 machinedblocks that are clamped together. One of the blocks has amachined recess though the thickness. This is illustratedin Figure 10.9.1.

10.9.6 Specimens

10.9.6.1 Butter plates, if necessary. If plate butteringis employed the details of the buttering procedure shallbe described in the test report. Three (3) layers is suffi-cient to minimize the effects of base plate dilution.

10.9.6.2 Machine the test block to 4 in by 5 in by 2 in(101 mm by 126 mm by 50 mm) thick, with a maximumaverage roughness of 125 microinches (3 micrometers),and final dimensions as shown in Figure 10.9.1.

10.9.6.3 Bake the samples at least 5 h at a minimumof 550°F (288°C) for hydrogen removal. If there is anoxide coating, it should be cleaned with a power brush orequivalent prior to testing.

10.9.7 Procedure

10.9.7.1 A minimum of three samples should bewelded for each test. Preheat samples for at least 4 h to25°F (–4°C) above the anticipated test temperature. Thesample block should be removed from the oven, thenplaced in a test fixture or simply clamped together. Thesamples are then tightened together and welding can bedone once the test temperature is reached. Either temper-ature crayons or digital temperature probes are permissi-ble for temperature measurement.

10.9.7.2 Weld across the gap a minimum of 4 in(101 mm) total weld length. Welding parameters shouldfollow manufacturer’s suggested welding procedures.

10.9.7.3 After welding, the test assembly must sit aminimum of 24 h in the test fixture or clamp.

10.9.7.4 Examination for Cracks. Penetrant testing,heat tinting or other methods may be used to determinethe extent of cracking. One other method is to break thetest assembly and note whether it did not crack or thedegree to which it cracked based on the predeterminedtesting criteria.

10.9.7.5 The samples can be re-used indefinitely, pro-vided that they are baked out between successive tests.This is to remove the hydrogen introduced during thetesting. This normally entails grinding away some weldmetal or machining after grinding.

10.9.7.6 If a sample cracks at a certain test tempera-ture, the next test should be run at a higher temperature.If the sample doesn’t show cracks at a given preheat tem-



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98

perature, the next temperature should be done with alower preheat.

10.9.7.7 As soon as the “cut-off” point is knownbetween cracking and noncracking samples, the test iscomplete for that particular electrode.

10.9.8 Report

10.9.8.1 In addition to the requirements of the norma-tive references, the report shall include the following:


(2) Materials identification including base metalspecification and filler metal specification;

(3) Specimen thickness and width;

(4) Specific test temperatures performed;

(5) Number of tests per condition or lot;

(6) The number, type, size, and location of defects (ifany); and

(7) Observations of unusual characteristics of thespecimens or procedure.



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99

Note: Surface finish to be 125 microinches (3 micrometers) Ra maximum.

Figure 10.9.1—Specimen Dimensions and Test Set-Up



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CLAUSE 11. PROCESS SPECIFIC TESTS AWS B4.0:2007

100

11. Process Specific Tests

11.1 Stud Weld Test11.1.1 Scope

11.1.1.1 This subclause covers mechanical testing ofstud welds. When testing of stud welds is required, theprocedure shall conform to this standard. This standarddoes not specify requirements or acceptance criteria.

11.1.1.2 When specified, this standard is applicable tothe following:

(1) Qualification of materials, welding operators, andwelding procedure;

(2) Information, basis of inspection and fabricationquality control (when acceptance criteria have beenestablished); and


11.1.1.3 When these tests are specified, the followinginformation shall be furnished:


(2) The specific tests and number of specimens thatare required;

(3) Base metal specification/identification;

(4) Position of welding;

(5) Stud analyses or specification (part number), orboth;

(6) Type of testing;

(7) Acceptance criteria; and

(8) For bend testing, the maximum angle of bendmust be specified, and for torque testing, the torque to beused must be specified.


AWS Documents:

AWS C5.4, Recommended Practices for StudWelding

AWS D1.1, Structural Welding Code—Steel

11.1.3 Summary of Method. The specimen is tested byone of two methods:

(1) The stud is bent by striking with a hammer orbending it using a length of tube or pipe, or

(2) A tensile load is applied to the stud using anappropriate fixture. This commonly is accomplished byuse of a torque wrench and a stand-off sleeve.

11.1.4 Significance

11.1.4.1 Mechanical testing of arc welded studs isused to evaluate weld soundness, tensile properties, andductility of the stud weld.

11.1.4.2 These tests are primarily used as a weldingprocedure qualification method to evaluate weldingparameters and surface preparation.

11.1.5 Apparatus. Apparatus used shall be capable offirmly holding the test assembly and applying the bend-ing force or torque as needed.

11.1.6 Specimens

11.1.6.1 Test specimens shall be prepared by weldingthe studs being tested (qualified) to specimen plates ofthe appropriate base metal as specified in 11.1.1.3.

11.1.6.2 Test specimens shall be made using theappropriate automatic timing, voltage, current, and gunsettings for lift and plunge as recorded in 11.1.1.3.

11.1.7 Procedure. The following are two test proceduresas specified in Part 11.1.3:

(1) Bend Testing. The required number of weldedspecimens shall be tested by bending the required num-ber of degrees from their original axis. Bending may bedone by striking the stud with a hammer or by bending itusing a length of tube or pipe as shown in Figure 11.1.1;and

(2) Torque Testing. The required number of studwelded specimens shall be tested by applying a torqueusing equipment as shown in Figure 11.1.2. A steelsleeve or washers, of appropriate size are placed over thestud. A nut of the same material as the stud is tightenedagainst the washer bearing on the sleeve, using a torquewrench. Tightening the nut applies the tensile load to theweld. Torque is applied until the specified level isreached or the weld fails. The results of this test may besignificantly affected by friction. Care should be taken tominimize this effect.

11.1.8 Report. In addition to the requirements of appli-cable documents, the report shall include the following:

(1) Test results and observations,

(2) The information listed in Part 11.1.1.3, and

(3) Drawings showing shapes and dimensions of studsand arc shields.



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AWS B4.0:2007 CLAUSE 11. PROCESS SPECIFIC TESTS

101

Figure 11.1.1—Equipment for Bend Tests for Welded Studs



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102

Figure 11.1.2—Equipment for Applying a Tensile Load to a Welded Stud Using Torque



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103

11.2 Resistance Welding Test7

11.2.1 Scope

11.2.1.1 This subclause covers the destructive testingused to determine the weld quality and mechanical prop-erties of resistance spot, seam, and projection welds.

When testing of resistance welds is required, the testspecimens and procedure shall conform to this standard.

This standard does not specify requirements or accep-tance criteria.

11.2.1.1 This standard is applicable to the following,where specified:

(1) Qualification of materials, welding personnel,welding procedures;

(2) Information, specification of acceptance, manu-facturing quality control; and


11.2.1.2 When this standard is used the followinginformation shall be furnished:


(2) The specific types and number of specimensrequired;

(3) Base metal specification and thickness;

(4) Electrode material, diameter, and shape;

(5) Base metal surface condition; and

(6) Postweld temper time.


AWS Documents:

AWS C1.4M/C1.4, Specification for ResistanceWelding of Carbon and Low-Alloy Steels


11.2.3.1 Weld Quality Tests. Three tests used todetermine the quality of resistance welds are:

7 Test procedure adopted from AWS C1.1M/C1.1:2000,Recommended Practices for Resistance Welding.

(1) Peel Test. The peel test is used to determine theweld button diameter and fracture mode of spot and pro-jection welds;

(2) Bend Test. This test, which was developed foraluminum and its alloys, is used for a quick check of pro-duction spot weld soundness, particularly for freedomfrom cracks or micro fissures. The bend test is not pre-cise enough to calibrate equipment, evaluate machineperformance, or to set-up and qualify welding schedules.It is intended as a supplement to the shear or peel tests. Itcan be performed with equipment which is readily avail-able in most shops and requires only visual examinationof the specimen; and

(3) Chisel Test. The test consists of forcing a toolinto the lap on each side of the weld until the lap jointseparates.

11.2.3.2 Mechanical Property Tests. The followingtests are used to assess the mechanical properties forspot, seam, and projection welds:

(1) Tension-Shear Test. This test consists of pulling atest specimen in tension to destruction on a standard ten-sile testing machine and determining its tension-shearcharacteristics;

(2) Tension Test. The purpose of the tension test is toprovide a method to determine the spot weld strengthunder tensile loading;

(3) Cross-Joint Tension Test. This form of tensiontest is designed to stress the weld in a direction normal tothe surface of the material so that tension at right anglesto the plane of the joint is produced;

(4) U-Specimen Tension Test. The purpose of this testis to also determine the tension strength of spot weld butis limited to base metal thicknesses and material that canbe readily bent into a U-shape;

(5) Pull Test. The pull test determines the resistanceof the welded joint to the opening mode of fracture. Thistest may also be referred to as a “90° peel test”;

(6) Torsion Shear Test. The torsion-shear test may beused where the strength and ductility of a spot weld isrequired;

(7) Impact Test. The impact test differentiatesbetween degrees of weld resistance to fracture underimpact load. Five types of spot weld impact tests aredescribed in this standard;

(8) Fatigue Test. This test is used to evaluate thefatigue performance of spot and projection welds for cer-tain applications; and



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104

(9) Pillow or Pressure Test. This test is used to deter-mine the leak-tightness of seam welds. The test can alsobe used to determine the fatigue strength of the weldedjoint under cyclic pressures.

Weld quality and mechanical property testing of resis-tance spot and seam welds are described further in 11.2.7and 11.2.8.

11.2.4 Significance. The weld quality and mechanicaltests described herein involve testing of welded speci-mens rather than the actual welded part. The test speci-mens should be representative of the production partswith respect to material, size, shape, thickness combina-tion, surface condition or preparation, contact overlap,and weld spacing (spot and projection welds) or weldsper inch (mm) (seam welds). A spot or projection weldedtest specimen may require only one weld if there is nosignificant shunt current effect caused by adjacent weldsduring welding of the actual parts.

11.2.5 Apparatus. The various fixtures, apparatus, andmachines required for the performance of weld qualityand mechanical property testing of spot and seam weldsare described in 11.2.7 and 11.2.8.

11.2.6 Specimens

11.2.6.1 Weld Quality Test Specimens. The detailsof the test specimens are found in the following figures:

(1) Peel test specimens are shown in Figure 11.2.1,

(2) Bend test specimen is shown in Figure 11.2.4, and

(3) Chisel test specimen is illustrated in Figure 11.2.5.

11.2.6.2 Mechanical Property Spot Weld TestSpecimens. The details of the test specimens are foundin the following figures:

(1) Tension-shear test specimen is shown in Figure11.2.6,

(2) Cross-joint tension test specimen is shown in Fig-ure 11.2.8,

(3) U-specimen tension test specimen is shown inFigure 11.2.11,

(4) Pull test specimen is illustrated in Figure 11.2.13,

(5) Torsion-shear test specimen is shown in Figure11.2.14,

(6) Tension-shear impact test specimen is shown inFigure 11.2.6,

(7) Cross-joint drop-impact test specimen is shown inFigure 11.2.15,

(8) U-specimen shear-impact test specimen is shownin Figure 11.2.11,

(9) U-specimen tension-impact loading test specimenis shown in Figure 11.2.11, and

(10) Fatigue test specimen is shown in Figure 11.2.6.

11.2.6.3 Mechanical Property Seam Weld TestSpecimen. The details of the test specimens for seamwelds are found in the following figures:

(1) Tension-shear test specimen is shown in Figure11.2.6, and

(2) Pillow or pressure test specimen is shown in Fig-ure 11.2.20.

11.2.7 Procedure for Weld Quality Tests. Proceduresfor the weld quality tests are discussed below:

(1) Peel Test. The test consists of peeling apart a testspecimen as shown in Figure 11.2.2. The specimen con-tact overlap should be large enough to allow the speci-men to be gripped and peeled apart. To determine thecurrent shunting effect, several spot welds can be madeusing the desired spacing. The sample is cut transverselybefore peeling starts, using the last weld made as the testsample. Three welds are recommended for this adapta-tion as shown in Figure 11.2.1. The size of the weldbutton can be measured, as shown in Figure 11.2.3, todetermine if it meets the minimum requirement;

(2) Bend Test. The test consists of bending a testspecimen which is removed from a routine micro-sectioncontaining three welds as shown in Figure 11.2.4. Thetest specimen is bent along its length to the angles shownto produce a concentration of the bending stresses suc-cessively in each of the three welds. Before bending, theedges of the specimens should be rounded and smoothedto remove burrs. After bending, the specimen is exam-ined for the presence of cracks or any other surfacedefects. This test may also be used for seam welds; and

(3) Chisel Test. This simple test consists of forcing atool into the lap on each side of the weld until the lapmetal separates, as shown in Figure 11.2.5. A weld isconsidered acceptable if it has an average button diame-ter equal to or greater than a specified value. The buttonsize is determined in the same manner as in the peel test.This test differs from the peel test in that actual produc-tion parts, selected at random, are evaluated.

11.2.8 Procedures for Mechanical Property Tests

11.2.8.1 Spot Weld Tests. The procedures to testmechanical properties for spot welds are discussedbelow:

(1) Tension Shear Test. The test specimen is made byoverlapping two strips of metal and joining them by asingle weld. The dimensions of the test specimen areshown in Figure 11.2.6. For specimens 0.10 in (2.6 mm)



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105

thick and over, it is suggested that pads be attached tospecimens to avoid bending in the grips of the testingmachine.

The ultimate strength of the specimen and the mode offailure, such as shearing of the weld metal, or tearing ofthe base metal, and type of fracture (ductile or brittle) isdetermined. It may also be desirable to measure andreport the bend angle between the weld interface and thetensile axis at fracture, as shown in Figure 11.2.7. Notethat this angle may also be referred to as the angle oftwist. The bend angle value is an important parameterwhich not only characterizes the stress conditions and theplastic deformation of the weld interface and adjacentbase metal, but also can be correlated with the fracturemode of the welded joint. Normally, a small bend angleis associated with weld interface shear failure. A largebend angle is associated with the fracture of the basemetal adjacent to the weld;

(2) Tension Test. This test is used to determine thespot weld strength under tensile loading. The ultimatestrength of the weld, the diameter of the weld button, andthe method of fracture can also be determined. The ulti-mate tensile strength determined by this test is a bettermeasure of sensitivity to embrittlement due to stress con-centration at the spot weld than is the tensile shearstrength obtained with the tensile shear test. The ratio ofthe tensile strength to the tension shear strength is fre-quently referred to as the ductility of the weld. Two typesof tension tests, the cross-joint tension test and the U-specimen tension test, are used as specified by the designrequirements of the part being welded and the testing fix-tures available;

(3) Cross-Joint Tension Test. This test is designed toapply a tensile stress to the spot weld in a direction nor-mal to the surface of the material. Dimensions of thewelded cross-joint tension specimens are shown in Fig-ure 11.2.8. Special holding fixtures are constructed toapply tension normal to the specimens.

The fixture for holding the 2 in × 6 in (50 mm × 152 mm)cross specimen of Figure 11.2.8A is shown in Figure11.2.9. The fixture is intended for sheet thicknesses up to0.19 in (4.8 mm).

Various methods of holding the fixture in the testingmachine may be used, such as pin connections, wedgegrips, or threaded-end testing fixture. A self-aligning fea-ture is desirable and precautions should be taken to pre-vent the specimen from slipping in the holding fixture.

The fixture for holding the 3 in × 8 in (76 mm × 204 mm)cross-joint specimen of Figure 11.2.8(B) is shown in Fig-ure 11.2.10. This fixture is intended for thicknesses over

0.19 in (4.8 mm) thick. Figure 11.2.10(B) shows a spec-imen in the lower portion of the test fixture.

Tension at right angles to the plane of the joint is pro-duced by applying compression to the fixtures holdingthe specimens. The U-shaped yokes with the hold downscrews are used to partially restrain the specimen frombending by introducing semifixed ends to the beam rep-resented by each separate plate. Figure 11.2.10(B) showsthe specimen completely assembled in the fixture withthe compression head of the testing machine in contactwith the fixture and ready to apply load to the specimen;

(4) U-Specimen Tension Test. A tension test may alsobe made on U-shaped specimens as shown in Figure11.2.11. The U-section specimens are welded as shownand pulled to destruction in a standard tensile testingmachine. Supporting or spacer blocks must be provided,as shown in Figure 11.2.12, for confining the sample sothat loading takes place at the weld. This test is limited tothose thicknesses and metals that can readily be bent tothe radius indicated. For magnesium, high-strength alu-minum alloys, and other alloys that cannot tolerate theindicated radius of bend, the radius must be increased toa suitable value;

(5) Pull Test. The pull test is used to determine theresistance of the welded joint to the opening mode offracture. Tensile load is applied at a 90° angle to the jointinterface as shown in Figure 11.2.13. It should be notedthat this test may also be referred to as a “90° peel test.”

For this test, a conventional tensile testing machine isused to provide the tension force. The grips serve as rein-forcement plates to minimize the elongation of the speci-men in regions outside the weld. The distances betweenthe sheets surfaces of the welded joint, positioned in thehorizontal plane (at 90° to the tension axis), and the adja-cent end surfaces of the grips should be sufficiently smallto minimize the elongation, but large enough so that thegrip ends do not interfere with the deformation of thewelded joint during the test. In preparation of a 90° pullarm, the weld nugget should not be disturbed. This canbe achieved by clamping the nugget of the spot weldspecimen in a vise so that the edge of the vise is alignedwith the “pull edge” of the nugget, and bending one sheetof the specimen to 90° with respect to the other sheet.The distance from the load axis of the pull arm to thenugget’s pull edge should be equal to the minimum bendradius of the metal to avoid cracking. For a given mate-rial and temper, the selected or experimental minimumbend radius should be the same for a data comparison.For ductile metals, the minimum bend radius of curva-ture should not exceed the thickness of one of the weldedsheets;



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106

(6) Torsion Shear Test. A torsion-shear test for evalu-ating spot welds may be used where a measure of thestrength and ductility is required. A typical set-up for thistest is shown in Figure 11.2.14. Torsional shear isapplied on the weld of a square test specimen by placingthe specimen between two recessed plates. The upper(gate) plate is held rigid by a hinge while the lower plateis fastened to a rotating disk. After the specimen isplaced in the square recess of the lower plate, the upperplate is closed over it and locked in position. Torque isapplied by means of a rack and pinion attached to thedisk. It is important that the upper and lower sheets of thespecimen be engaged separately by the two plates andthat the weld be centrally located with respect to the axisof rotation.

Three values are determined for the weld area:

(a) Ultimate torque required to twist the weld todestruction [computed by multiplying the maximum loadin pound-force (Newtons)] by the moment arm in inches(mm),

(b) Angle of twist at ultimate torque (measured bythe angle of rotation at maximum load), and

(c) Weld diameter (measured after the test speci-men is broken).

The weld strength can be determined using the ultimatetorque and weld diameter, and the ductility by the angleof twist.

It is possible to use the test values obtained (ultimatetorque, angle of twist, and weld diameter) to indicatequality. This may be done by using the standard torsionalformula:

St = Mc/I

whereI = moment of inertia [in4 (m4)],St = Torsional shear stress [psi (Pa)],M = torque [in pound-force (N-m)], andc = distance from external fiber to central axis [in

(m)].

The torsional shear stress values obtained for the externalfibers, termed the modulus of rupture, are directly pro-portional to the tension shear stress. The modulus of rup-ture, as determined by actual tests on low-carbon steels,was found to be approximately twice the tension shearstress.

An additional benefit of torsional testing is that it alsoallows the determination of tension shear strength byusing the following equations:

St = 2SL

whereSL = tension shear stress [psi (Pa)], andMc/I = 2L/A.

whereL = straight shear load [pound-force (N)], andA = cross-sectional area [in2 (m2)].

Substituting ultimate torque (T) for torque (M), and L forstraight shear load yields:

Where solving for L gives the following result:

L = 2T/D

or,

Shear load [pound-force (N-m)] =

The above formula gives the approximate relationbetween shear strength and torque required to shear theweld, thereby permitting evaluation of the shear strengthby torsional testing, or calculating the ultimate torquefrom the shear load.

When tested and computed as indicated above, thestrength values for single spot welds may be determined.

(7) Impact Tests. Five types of impact tests aredescribed here:

(a) Tension Shear-Impact Test. This test is limitedto thicknesses up to 0.125 in (3.2 mm). A satisfactoryshear-impact test for spot welds may be obtained byusing the 2 in × 6 in (50 mm × 152 mm) tension shearspecimen (see Figure 11.2.6), and a modified 11 pound-force to 22 pound-force (50 N to 100 N) pendulum-typeimpact testing machine. To satisfactorily test welds insheets up to and including 0.125 in (3.2 mm) thickness, itis necessary to have pendulum bobs of different weights.

In this type of test, the specimen is held by serratedwedge grips in the special pendulum bob and cross-headattachments. When the machine is operated, both thecross-head and bob, which are connected by the weldedspecimen, fall until the cross-head is caught by adjust-able anvils at the bottom of the pendulum swing. Thependulum bob is free to continue its swing, and will doso, provided sufficient energy is available to fracture thespecimen. The residual swing of the pendulum indicatesthe impact load, in foot-pound-force (N-m), necessary tobreak the weld. Care should be taken to properly tightenthe wedge grips so that no errors are introduced by slip-page of the specimen during the test. If grip slippage is a

TD/2πD4/32------------------ 2L

πD2/4---------------=

2 {ultimate torque [in pound-force (N-m)]}Weld diameter [in (m)]

-------------------------------------------------------------------------------------------------------



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107

serious problem, pin connections may be used to supple-ment the grips. The striking surface of the cross-head andthe impact-receiving surface of the anvil should be per-pendicular to the longitudinal axis of the specimen topreclude errors caused by twist load. Tests may be madeat various velocities which should be no less than 10 ft/s(3 m/s) or more than 20 ft/s (6 m/s). Velocity shouldalways be stated as a maximum tangential velocity of thecross-head striking surface. The impact value should betaken as the energy absorbed in breaking the weld, and isequal to the difference between the energy in the entirestriking unit, which may, for example, consist of pendu-lum, pendulum bob, specimen, and cross-head, at theinstant of impact with the anvil and the energy remainingafter breaking the weld. For maximum energy, thekinetic energy imparted to the tooling should be takeninto account. Similar to the requirements for tensionshear test, it is desirable to determine and report thebending angle at fracture as measured after the test.

When making shear-impact tests, some of the energy isabsorbed in plastic deformation of the sheets. In order tocontrol the extent of this deformation, the distancebetween grips should be not less than 4.9 in (125 mm)nor more than 5.1 in (129 mm).

Since large changes in spot weld impact strength occurwith relatively small changes in sheet thickness and weldsize, the coverage obtained by any one pendulum bobassembly is limited.

(b) Cross-Joint Drop-Impact Test. Since the rangeof the ordinary pendulum-type impact testing machinewill not permit tension shear impact tests to be made onspot welded sheets of thicknesses greater than 0.125 in(3.2 mm), a different procedure must be used to applyimpact loads to welds in heavier gage metals. The mostcritical direction in which an impact load may be appliedto spot welds in heavy plate is in a direction normal tothe plate surfaces. This may be accomplished using a testspecimen similar to that used for the cross-joint tensiontest with added reinforcement as shown in Figure11.2.15.

The principal components of a drop weight impactmachine are a vertically guided, free falling weight, arigidly supported anvil, and a pair of calibrated springsplaced below the specimen or other type of force trans-ducer arrangement to measure the remaining energy ofthe weight after the weld fractures (see Figure 11.2.16).The lower portion of the weight is designed as a fork toassure that the impact of the weight will be appliedequally to both sides of the lower plate of the specimen.The width of the opening between the two prongs of thefork of the weight is made 3.12 in (79 mm), 0.12 in(3 mm) greater than the specimen plate width of 3.0 in

(76 mm) to permit the small clearance between the insidesurfaces of the fork and the clamped upper plate.

When calibrated springs are used to measure the remain-ing energy after the test, the maximum deflection of thesprings may be indicated by an aluminum push rod mov-ing between a pair of bronze friction plates. The amountof friction may be controlled by means of spring loadedmachine screws. An arm on the aluminum push rod pro-vides a convenient place for an indicator dial gauge to beused to measure the maximum deflection of the springs(see Figure 11.2.16). A calibration curve for residualenergy may be obtained by dropping the weight fromvarious heights corresponding to various potential ener-gies of the moving system.

The results obtained with the cross-joint drop-impact testare subject to two types of error. Both of these are con-cerned with the behavior of thinner plates and the softertypes of steel. One source of error is the inability torestrain the lower plate against bending. In this case, ifthe lower plate is thin and soft, too much bending will beproduced, and either the specimen will not break or alarge portion of the impact energy will be absorbed inbending the plate. Although the ability of a weld to forcethe plate to bend may be a good indication of weld qual-ity, the resultant impact energy absorbed by bending willnot be a good measure of the weld strength. On the otherhand, severe plastic deformation of the plate material inthe vicinity of the weld is a much better indicator of weldquality. Therefore, plate bending at some distance fromthe weld should be avoided. The second source of errorin impact testing is bending of the upper plate and slip-page of the specimen in the clamps. Both of these causeabsorption of additional energy, and a true measure ofweld toughness is not obtained.

In order to avoid the possibilities for errors mentionedabove, two methods may be used to minimize bendingand grip slippage in the upper plate. One is to provideserrated jaws for clamping to prevent slippage. The otheris to place another plate directly over the upper plate andto attach these plates at their ends by additional spotwelds, as illustrated in Figure 11.2.15. In this case, theextra plate is in compression during the test, preventingexcessive plate bending due to grip slippage. In the test-ing of a thin plate welded to a thicker one, the heavierplate is arranged to be struck by the falling weight. Theprecautions as mentioned above should be used with theupper plate to ensure a satisfactory impact test. If bothplates are thin and soft, it may be necessary to reinforcethe lower plate in a manner similar to that used to stiffenthe upper plate.

(c) U-Specimen Shear-Impact Test. This test uti-lizes the specimen made by joining two U-shaped sec-



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tions back to back by a single spot weld as shown inFigure 11.2.11. The specimen is dynamically loaded in apendulum type impact testing machine with at least a 220foot-pound-force (300 N-m) capacity. The test fixture isso designed that the force applied in fracturing the speci-men is essentially in shear as shown in Figure 11.2.17.The operation of this test is similar to that described forthe tension shear-impact test. The energy [foot-pound-force (N-m)] consumed in fracturing the specimen andthe mode of failure are recorded.

(d) U-Specimen Tension-Impact Loading Test.This test also utilizes the U-shaped test specimen shownin Figure 11.2.11. In this case, the test fixture is so de-signed that the forces applied in fracturing the specimenare in tension as shown in Figure 11.2.18. In all otherrespects, this test is the same as the U-specimen shear-impact test.

(e) Instrumented Impact Test. The instrumentedimpact test electronically records the load versus timeand the impact energy versus time traces to follow thedynamic fracture process of the specimen. The instru-ment consists of:

1. Load transducer placed on the pendulumbob to sense the specimen loading,

2. Electronic signal conditioning circuit, and

3. Graphic recording equipment for plottingthe transducer output versus time.

For certain alloys and specimen configurations, load sig-nal oscillation may occur and become excessive. Theaccuracy of load values is assured if sufficient dampingis achieved. For an accurate determination of the peakload, it should be required that the time to the peak loadis at least three times the period of oscillation.

(8) Fatigue Test. The Fatigue test is performed usingthe shear test specimen (see Figure 11.2.6). The speci-men is mounted in the fatigue tester using utmost care toalign the weld with the force center. Fatigue tests of spotand projection welds are often conducted with a ratio ofminimum stress to maximum stress of 0.1. Maximumtensile load should never occur at less than 25% of themachine’s operating range. There are different types offatigue testing machines, such as:

(a) Mechanical (eccentric crank, power screws,rotating masses) type;

(b) Hydraulic or electrohydraulic type; and

(c) Electromechanical or magnetically driven type.

A typical fatigue test set-up is shown in Figure 11.2.19.

The selected fatigue testing machine should permitcycling between the intended stress or strain limits. Forconstant-amplitude low-cycle (less than 105 cycles)fatigue, the machine control stability should be such thatthe respective stress or strain limit is repeatable fromcycle to cycle to within 0.5% of the average control limitand repeatable over the test duration to within 2% of theaverage control limit. Either strain rate or frequency ofcycling should be constant for the duration of each test.Although constant strain rate testing is often preferred toconstant frequency testing, the latter may be of greaterpractical significance to the fatigue analysis of resistancewelds for certain applications. In high-cycle fatigue tests,the test load should be monitored continuously in theearly stage of the test and periodically maintained.

The machine should have minimal backlash in the load-ing train. The varying stress, as determined by a suitabledynamic verification, should be maintained at all timesto within 2% of the machine operating range. Below acertain frequency (e.g., 170 Hz depending on the metal),the fatigue effects due to frequency are negligible.Above this frequency, the effect of frequency on thefatigue strength may be significant and should bereported particularly if the materials are strain rate sensi-tive. As in the tension shear test, the rotation (twisting)angle (see Figure 11.2.7) of the weld interface should berecorded (e.g., by photographs) to characterize the stressconditions and plastic deformation, and to correlate itwith the fracture mode of the welded joint and adjacentbase metal.

To evaluate the fatigue performance of the welded joint,the following information should be reported:

(1) Total number of cycles to failure (Nf), whichshould be accompanied by the following information:

(a) The failure definition used in the determina-tion of Nf (e.g., crack size or complete separation),

(b) Location of crack initiation,

(c) Frequency of cycling and shape of load timecurve

(d) Mode of control (e.g., load, stress, continuousstrain control, or strain limit control.

(e) Axial stress ratio R, where:

For zero minimum axial stress, R = 0

(2) Rotation angle immediately before or at failure.

R Minimum axial stressMaximum axial stress-----------------------------------------------------=



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11.2.8.2 Seam Weld Tests

(1) Tension Shear Test. To determine the shearstrength of a seam weld, the tension shear test specimen(see Figure 11.2.6) previously described should contain aseam weld, in place of the spot weld, perpendicular to theaxis of the tensile load.

(2) Pillow Test or Pressure Test. Seam welding is anextension of spot welding where the spots provide a con-tinuous weld. This type of weld is usually employedwhere leak-tightness is required. A test simulating theservice conditions of the welded joint furnishes the bestmeasure of the weld quality.

For this purpose, two flat plates of the same thickness, asused in production, are prepared and seam weldedaround the outside edge, sealing the space between theplates. A pipe connection is then welded to a hole drilledin the top plate as shown in Figure 11.2.20. After theassembly is attached to a hydraulic system, pressure isapplied.

The pillow can be so distorted as to cause excessive load-ing in some spots with little loading in other spots. Con-sequently, it may be necessary to restrict deformation ofthe pillow by inserting a plate above and below it whiletesting, particularly in soft or thin material.

The measure of a good weld is no leakage at a prescribedpressure or when failure occurs in the base metal. Thepillow specimen can be tested under cyclic pressures todetermine the fatigue strength of the welded joint.

11.2.8.3 Projection Weld Test. Weld quality andmechanical property tests for resistance spot welds maybe applied for production welds. However, some modifi-cations may be required due to workpiece geometry ordissimilarity in metal thickness joined.

11.2.9 Report

11.2.9.1 In addition to the requirements of the appli-cable documents (see 11.2.2) the report shall include thefollowing for each specimen tested:

(1) The specific test and number of specimensrequired;

(2) Base metal specification and thickness;

(3) Base metal surface condition;

(4) Electrode material, diameter, and shape;

(5) Welding parameters and schedule; and

(6) Postweld temper time.

11.2.9.2 Test data for spot and seam welding shouldbe recorded on test results sheets similar to Figures11.2.21 and 11.2.22.

11.2.10 Commentary. During chisel testing of spotwelds care should be exercised not to score/nick any por-tion of the weld nugget. The slightest score/nick on aweld nugget may cause a notch effect/stress riser andresult in premature fracture initiation and be indicative ofinadequate nugget size.

When “push out” testing of production welds, the man-drel ID shall not exceed the OD of the nut or stud headby a dimension greater than 0.125 in (3 mm). When anoversize mandrel is used the first projection to yield willusually pull a nugget and the remaining nuggets will faildue to fracture, especially in base metal thickness lessthan 0.2 in (5 mm). This is due to base metal deformationfollowing the yielding of the first nugget, and the non-uniform loading of the remaining nuggets.



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Source: Adapted from American Welding Society C1 Committee on Resistance Welding, AWS C1.1M/C1.1:2000, RecommendedPractice for Resistance Welding, Miami: American Welding Society, Figure 4.

Figure 11.2.1—Peel Test Specimen

T (Thickness) W L

Din (mm) in (mm) in (mm)

Up to 0.0290.030 to 0.0580.059 to 0.125

Up to (0.74)(0.76 to 1.47)(1.5 to 3.2)

0.631.001.50

(16)(25)(38)

234

(50)(76)

(102)

See minimum weld spacing in Recommended Practice



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Figure 11.2.2—Peel Test


Figure 11.2.3—Measurement of a Weld Button Resulting from the Peel Test



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Figure 11.2.4—Bend Test Specimen

T (Thickness) W L

Din (mm) in (mm) in (mm)

Up to 0.0290.030 to 0.0580.059 to 0.125

Up to (0.74)(0.76 to 1.47)(1.5 to 3.2)

0.631.001.50

(16)(25)(38)

234

(50)(76)

(102)

See minimum weld spacing in Recommended Practice



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Figure 11.2.5—Spot Weld Chisel Test



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Figure 11.2.6—Specimen for Tension Shear Test and Tension Shear Impact Test

T (Thickness of Thinner Sheet) W (Specimen Width) L (Recommended Length

in (mm) in (mm) in (mm)

Up to 0.0300.031 to 0.0500.051 to 0.1000.101 to 0.1300.131 to 0.1900.191 and over

Up to (0.76)(0.79 to 1.27)(1.3 to 2.5)(2.6 to 3.3)(3.3 to 4.8)

(4.8) and over

0.630.751.001.251.502.00

(16)(19)(25)(32)(38)(50)

334556

(76)(76)

(102)(127)(127)(152)



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Figure 11.2.7—Twisting Angle γ at Fracture in Tension Shear Test



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Figure 11.2.8—Cross-Tension Test Specimens



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Figure 11.2.9—Fixture for Cross-Tension Test (for Thickness up to 0.19 in [4.8 mm])



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Figure 11.2.10—Fixture for Cross-Tension Test (for Thickness 0.19 in [4.8 mm] and Over)



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Figure 11.2.11—Specimen for U Specimen Tension Test and U Specimen Shear Impact Test

T (Thickness) W A B D E Ra

in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)

Up to 0.100 Up to (2.54) 1 (25) 1 (25) 0.5 (13) 0.33 (8.3) 1 (25) 0.16 (4.0)

0.101 and over (2.56) and over 2 (50) 2 (50) 1.0 (25) 0.56 (14.3) 2 (50) 0.25 (6.4)

a For magnesium, high-strength aluminum alloys and other alloys that cannot tolerate these radii, the radius must be increased to asuitable value within the limits of the capability of the particular material. It is desirable to form these specimens without the necessity ofheating as this will modify the results.



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Figure 11.2.12—U-Tension Test Jig

T (Thickness) W A B D E Ra L

in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)

Up to 0.100 Up to (2.54) 1 (25) 1 (25) 0.5 (13) 0.34 (8.7) 1 (25) 0.16 (4.0) 2.25 (57)

0.101 and over (2.56) and over 2 (50) 2 (50) 1.0 (25) 0.56 (14.3) 2 (50) 0.25 (6.4) 3.25 (82)

a For magnesium, high-strength aluminum alloys and other alloys that cannot tolerate these radii, the radius must be increased to asuitable value within the limits of the capability of the particular material. It is desirable to form these specimens without the necessity ofheating as this will modify the results.



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Figure 11.2.13—Pull Test (90° Peel Test)



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Figure 11.2.14—Test Specimen and Typical Equipment for Torsion-Shear Test



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Figure 11.2.15—Drop-Impact Test Specimen



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Figure 11.2.16—Drop-Impact Test Machine


Figure 11.2.17—Test Fixture for Shear-Impact Loading Test



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Figure 11.2.18—Test Fixture for Tension-Impact Loading Test



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Figure 11.2.19—Fatigue Testing Machine



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Source: Adapted from American Welding Society C1 Committee on Resistance Welding, AWS C1.1M/C1.1:2000, RecommendedPractice for Resistance Welding, Miami: American Welding Society, Figure 22

Figure 11.2.20—Pillow Test for Seam Welds



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RESISTANCE WELDING DATA SHEET

EQUIPMENT IDENTIFICATION

TYPE ____________________ SERIAL __________

TRANSFORMER NO. _______ RATING __________

CONTROL ___________________________________


Figure 11.2.21—Suggested Data Sheet for Resistance Spot and Projection Welding

SIDEA

SIDEB

MAT

ER

IAL

Thickness Weld Current

Approx. Analysis (type) S. C. Current

Tap and/or Phase Setting

Throat Opening

Surface Cond. Throat Spacing

Ultimate Strength Synchronous orNonsynchronous timingYield Strength

Elongation % Heat Time

Red. in Area % Squeeze Time

Hardness Cool Time

Material Hold Time

ELE

CT

RO

DE

Shape No. of Pulsations

Electrode Force

Squeeze Force

Forging Force

Tension Shear Test

Tension Test

SP

OT

Diameter

TORSIONAL

Yield Point

Overlap or Flange Ultimate

Spacing Mod. of Rupt.

PR

OJE

CT

ION

SizeContour

Degree Twist at Ult.

Indentation

Nugget Size

Other Tests:

Number

Location

Remarks: Photos



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RESISTANCE WELDING DATA SHEET

EQUIPMENT IDENTIFICATION

TYPE ____________________ SERIAL __________

TRANSFORMER NO. _______ RATING __________

CONTROL ________________


Figure 11.2.22—Suggested Data Sheet for Resistance Seam Welding

SIDEA

SIDEB

MAT

ER

IAL

Thickness Weld Current

Approx. Analysis (type) S. C. Current

Tap and/or Phase Setting

Throat Opening

Surface Cond. s Throat Spacing

Ultimate Strength Synchronous orNonsynchronous TimingYield Strength

Elongation % Heat Time

Red. in Area % Cool Time

Hardness Electrode Force

ELE

CT

RO

DE

Material Tension Shear Test

Shape Tension Test

TORSIONAL

Yield Point

Ultimate

Mod. of Rupt.

Degree Twist at Ult.

SE

AM

Roll Speed in per min (mm per min) Indentation

Spots per in (mm) Other Tests:

Width of Weld

MA

SH Overlap or Filler

Length of Weld

Remarks: Photos



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Controlled Thermal Severity Testing

Cottrell, C. L. M. “Controlled thermal severity crackingtest simulates practical welded joints.” Welding Jour-nal 33(6): 257-s, 1953.

Houldcroft, P. T. “A simple cracking test for use withargon arc welding.” British Welding Journal 2(12):471, 1955.

Pedder, C., and Hart, P. H. M. “CTS testing procedures:the present position.” The Welding Institute ResearchBulletin 16(9): 264–266, 1975.

British Standards Institution, BS 7363:1990, Methods forControlled Thermal Severity (CTS) Test and Bead-OnPlate (BOP) Test for Welds, 1990.

Cruciform Testing

American Welding Society, Welding Handbook, Vol. 2.Miami, Florida: American Welding Society, 1978.

Linnert, G. E. Welding Metallurgy, Carbon and AlloySteels, Third Edition, Vol. 2, 632–634. Miami: Amer-ican Welding Society, 1965.

Welding Research Council. Weldability of Steels, Ed.Stout and Doty: New York, NY: Welding ResearchCouncil.

Poteat, L. E. and Warner, W. L. “The cruciform test forplate-cracking susceptibility.” Welding Journal 39(2):70-s, 1960.

Implant Test

Sawhill, J. M. Jr., Dix. A. W. and Savage, W. F. “Modi-fied implant test for studying delayed cracking.”Welding Journal 53(12): 554s-560s, December, 1974.

Bryhan, A. J. “The effect of testing procedure on implanttest results.” Welding Journal 60(9): 169-s–176-s,September, 1981.

Karppi, R., Ruusila, J., Saton, K., Toyada, M., andVartiainen, K. Note on Standardization of ImplantTest. Research Reports IIW FINLAND: TechnicalResearch Centre of Finland, 1983. IX-1296-83.

Wong, R. J. “The effect of weld metal diffusible hydro-gen on the cracking susceptibility of HY-80 steel.”Hydrogen Embrittlement: Prevention and Control,ASTM STP 962, Raymond, ED., American Societyfor Testing and Materials. Philadelphia, pp. 274–286,1988.

Lehigh Restraint Test

Stout, R. D., Tor, S. S., McGready, L. J., and Doan, G. E.“Quantitative measurement of the cracking tendencyin welds.” Welding Journal 25(9): 522-s–531s, 1946.

Stout, R. D. and Doty, W. D. Weldability of Steel. NewYork: Welding Research Council, 1987.

Varestraint Testing

Savage, W.F. and Lundin, C.D. “The varestraint test.”Welding Journal 44(10): 435-s–442-s, 1965.

Savage, W.F. and Lundin, C.D. “Application of the vare-straint technique to the study of weldability.” WeldingJournal 45(11): 497-s–503-s, 1966.

McKeown, D. “Versatile weld metal cracking tests.”Metal Construction and British Welding Journal 2(8):351–352, 1980.

Annex A (Informative)Bibliography

This annex is not part of AWS B4.0:2007, Standard Methods for MechanicalTesting of Welds, but is included for informational purposes only.



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Lundin, C. D., Lingenfelter, A. S., Grotke, G. E., Less-mann, G. G., and Matthews, S. J. The VarestraintTest. Bulletin 280. New York: Welding ResearchCouncil, August, 1982.

Lin, W. “A model for heat-affected zone liquation crack-ing.” Welding in the World 30 (9/10): 236–242, 1992.

Lin, W., Lippold, J. C., and Baeslack III, W. A. “Anevaluation of heat-affected zone liquation crackingsusceptibility, Part I: Development of a method forquantification.” Welding Journal 72(4): 135-s–153-s,1993.

Oblique Y-Groove Testing

JIS Z 3158, Japanese Industrial Standards Committee,Method of Y-Groove Cracking Test.

Satoh K., Toyoda M., Ikita K., Nakamura A., and Mats-uura T., Prevention of weld crack in HY 80 heavyplates with undermatching electrodes and its applica-tion to fabricating penstock, July, 1978.

Suzuki, H., Cold cracking and its prevention in steelwelding, Transactions of the Japan Welding Society,vol. 9, No. 2, 1978.

WIC Test

Thorn, K., Lazor, R. B., and Graville, B. A., “Predictionof Weld Cracking Susceptibility,” AGA PR-140-136,Nov. 1981.

Wong, R. J., “Hydrogen Cracking Resistance of HighStrength Steels in Single Pass and Multipass Weld-ability Tests,” Proceedings of Symposium on Weld-ing and Weld Automation in Shipbuilding, pp. 33–46,Edited by R. DeNale, TMS Materials Week ’95 inCleveland Ohio, Oct. 29–Nov. 2, 1995.

Trough Test

Juers, Raymond H., “Investigation of MIL-14018Shielded Metal-Arc Weld Repair Procedures Usingthe Trough Weldability Specimen,” January 1975.



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B1. IntroductionThe American Welding Society (AWS) Board of Directorshas adopted a policy whereby all official interpretationsof AWS standards are handled in a formal manner.Under this policy, all interpretations are made by thecommittee that is responsible for the standard. Officialcommunication concerning an interpretation is directedthrough the AWS staff member who works with thatcommittee. The policy requires that all requests for aninterpretation be submitted in writing. Such requests willbe handled as expeditiously as possible, but due to thecomplexity of the work and the procedures that must befollowed, some interpretations may require considerabletime.

B2. ProcedureAll inquiries shall be directed to:

Managing DirectorTechnical Services DivisionAmerican Welding Society550 N.W. LeJeune RoadMiami, FL 33126

All inquiries shall contain the name, address, and affilia-tion of the inquirer, and they shall provide enough infor-mation for the committee to understand the point ofconcern in the inquiry. When the point is not clearlydefined, the inquiry will be returned for clarification. Forefficient handling, all inquiries should be typewritten andin the format specified below.

B2.1 Scope. Each inquiry shall address one single provi-sion of the standard unless the point of the inquiry

involves two or more interrelated provisions. The provi-sion(s) shall be identified in the scope of the inquiryalong with the edition of the standard that contains theprovision(s) the inquirer is addressing.

B2.2 Purpose of the Inquiry. The purpose of the inquiryshall be stated in this portion of the inquiry. The purposecan be to obtain an interpretation of a standard’s require-ment or to request the revision of a particular provisionin the standard.

B2.3 Content of the Inquiry. The inquiry should beconcise, yet complete, to enable the committee to under-stand the point of the inquiry. Sketches should be usedwhenever appropriate, and all paragraphs, figures, andtables (or annex) that bear on the inquiry shall be cited. Ifthe point of the inquiry is to obtain a revision of the stan-dard, the inquiry shall provide technical justification forthat revision.

B2.4 Proposed Reply. The inquirer should, as aproposed reply, state an interpretation of the provisionthat is the point of the inquiry or provide the wording fora proposed revision, if this is what the inquirer seeks.

B3. Interpretation of Provisions of the Standard

Interpretations of provisions of the standard are made bythe relevant AWS technical committee. The secretary ofthe committee refers all inquiries to the chair of the par-ticular subcommittee that has jurisdiction over the por-tion of the standard addressed by the inquiry. Thesubcommittee reviews the inquiry and the proposed replyto determine what the response to the inquiry should

Annex B (Informative)

Guidelines for the Preparation of Technical InquiriesThis annex is not part of AWS B4.0:2007, Standard Methods for Mechanical

Testing of Welds, but is included for informational purposes only.



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be. Following the subcommittee’s development of theresponse, the inquiry and the response are presented tothe entire committee for review and approval. Uponapproval by the committee, the interpretation is an officialinterpretation of the Society, and the secretary transmitsthe response to the inquirer and to the Welding Journalfor publication.

B4. Publication of InterpretationsAll official interpretations will appear in the WeldingJournal and will be posted on the AWS web site.

B5. Telephone InquiriesTelephone inquiries to AWS Headquarters concerningAWS standards should be limited to questions of a gen-eral nature or to matters directly related to the use of thestandard. The AWS Board Policy Manual requires thatall AWS staff members respond to a telephone request

for an official interpretation of any AWS standard withthe information that such an interpretation can beobtained only through a written request. Headquartersstaff cannot provide consulting services. However, thestaff can refer a caller to any of those consultants whosenames are on file at AWS Headquarters.

B6. AWS Technical CommitteesThe activities of AWS technical committees regardinginterpretations are limited strictly to the interpretation ofprovisions of standards prepared by the committees or toconsideration of revisions to existing provisions on thebasis of new data or technology. Neither AWS staff northe committees are in a position to offer interpretive orconsulting services on (1) specific engineering problems,(2) requirements of standards applied to fabricationsoutside the scope of the document, or (3) points notspecifically covered by the standard. In such cases, theinquirer should seek assistance from a competent engi-neer experienced in the particular field of interest.



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135

List of AWS Documents on Mechanical Testing of Welds

Designation Title

B4.0M Standard Methods for Mechanical Testing of Welds



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