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Weld Testing Laboratory Case Study
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BACKGROUND
Our Weld Testing Laboratory was requested to perform Charpy V-Notch Impact Testing, Corrosion Testing, Weld Ferrite Determination, Weld Microexamination and Vickers microhardness testing to document any evidence of detrimental weld related conditions.
 
SAMPLE IDENTIFICATION
ID Size Material Specification
2209-2 ¼" Plate Duplex Stainless API 938-C
 
SUMMARY of TEST RESULTS
 
Charpy Impact Testing
Location Size (mm) Temp Energy ft-lbs) Lat. Exp.
(.001")
Weld Centerline 10 x 5.0 -40°C 16 24
Weld Centerline 10 x 5.0 -40°C 16 23
Fusion Line 10 x 5.0 -40°C 51 68
Fusion Line 10 x 5.0 -40°C 44 58
Fusion Line + 2.5mm 10 x 5.0 -40°C 77 85
Fusion Line + 2.5mm 10 x 5.0 -40°C 69 79
Fusion Line + 4.75mm 10 x 5.0 -40°C 56 71
Fusion Line + 4.75mm 10 x 5.0 -40°C 88 93
 
Corrosion Testing

Test Temperature:     22°C          Test Duration:     24 Hrs.
Area (dm2) Wt Loss (mg) Corrosion Rate (mdd)
.307 0.0 0
.302 0.0 0
 
Percent Ferrite Testing – Automated Image Analysis
Location Ferrite Content
Weld Cap 52.5% ± 0.5%
Weld Mid-Thickness 53.0% ± 0.5%
Weld Root 50.0% ± 0.5%
HAZ of Base A at Root 61.5% ± 0.5%
HAZ of Base B at Root 62.0% ± 0.5%
Base A 51.5% ± 0.5%
Base B 51.0% ± 0.5%
 
Ferrite Testing
Weld Testing Laboratory
Photo 1: Mag: 500X; Etchant: Beraha Reagent Location: Weld at Cap
 
Weld Testing Laboratory
Photo 3: Mag: 500X; Etchant: Beraha Reagent Location: Weld at Root
 
Weld Testing Laboratory
Photo 5: Mag: 500X; Etchant: Beraha Reagent Location: HAZ of Base B at Root
 
Weld Testing Laboratory
Photo 7: Mag: 500X; Etchant: Electrolytic NaOH Location: Base B at Mid-Thickness
 
Weld Testing Laboratory
Photo 2: Mag: 500X; Etchant: Beraha Reagent Location: Weld at Mid-Thickness
 
Weld Testing Laboratory
Photo 4: Mag: 500X; Etchant: Beraha Reagent Location: HAZ of Base A at Root
 
Weld Testing Laboratory
Photo 6: Mag: 500X; Etchant: Electrolytic NaOH Location: Base A at Mid-Thickness
 
TEST RESULTS
Vicker’s Microhardness Testing
Weld Testing Laboratory
 
Indentation HVN-1kg
1 256
2 262
3 278
4 284
5 290
6 274
7 279
8 279
9 288
10 278
11 281
12 279
13 276
14 288
15 278
16 272
17 309
18 281
19 288
20 281
21 285
22 286
Indentation HVN-1kg
23 303
24 288
25 321
26 266
27 278
28 266
29 268
30 258
31 278
32 257
33 286
34 285
35 279
36 278
37 279
38 297
39 278
40 297
41 311
42 293
43 293
44 297
* Testing performed in accordance with ASTM A923 – Method B & C, E92 and E562 using Clemex Vision Analysis system.
 
Macro-Examination
The macro-examination revealed complete fusion between the weld and the base metal as well as between individual weld passes, however weld slag inclusions and a weld underfill condition was observed on both sides of the weld root (see Photos 8 - 10).
 
Weld Testing Laboratory
Photo 8: Weld rofile Etchant:                                                 Hot HCl solution
 
Weld Testing Laboratory
Photo 9: Mag: 50X; Etchant: Hot HCl solution Weld underfill condition (denoted with red arrow on Photo 8)
 
Weld Testing Laboratory
Photo 10: Mag: 50X; Etchant: Hot HCl solution Weld underfill condition (denoted with blue arrow on Photo 8)
 
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