UNIVERSITI TEKNOLOGI MARA

FAKULTI KEJURUTERAAN MEKANIKAL

_________________________________________________________________________
Program
:
Bachelor of Engineering (Hons) Mechanical (EM220)
Course
:
Applied Welding Engineering
Course Code :
MEM661
Lecturer
:
Assoc Prof Sunhaji Kiyai Abas
_________________________________________________________________________
Laboratory Report

DESTRUCTIVE TEST BEND TEST & NICK BREAK TEST / FRACTURE TEST
TO EVALUATE QUALIFY OF WELD ON BUTT & FILLET WELDS
No
Name
.
1. MOHAMED ANIQUE BIN MOHAMED AZIYEN

Student ID Number

Signature

2013879068

2.

WAN NURUL AFIFAH BINTI WAN TARMIZI

2013652462

3.

MOHD SUBARU BIN SUNARU

2013240806

4.

NURAKMAR BINTI ALIAS

2013632642

5.

MUHAMAD FIRDAUS BIN NOR AZIMAT

2013849484

Practical Session

: _____________ Staff certification : ________________

(Date)
(Signature)

Report Submission

: _____________ Staff certification : ________________

(Date)
(Signature)

CONTENTS
Page
No:

Marks
Allocat
ed

Marks
Obtain
ed

Assigned
Course
Outcomes
CO1/CO3

To Achieve
(CO1:
PO1,PO2,
PO3 &

PO10) / CO3:
PO6)
FRONT COVER
GRADING FORM
CONTENTS
4
1. Title
6
2. Objective(s)
15
3. Introduction (background and
theory)
10
4. Apparatus (with noble
description)
15
5. Experimental Procedure

25
6. Results & Data Analysis
15
7. Discussion of Results
5
8. Conclusion
3
9. Recommendation
2
10. References

TOTAL

100

CONTENTS OF THE LABORATORY REPORT & GRADING CRITERIA

Report Contents
1. Title
2. Objective(s)
3. Introduction
(background & theory)
4. Apparatus
5. Experimental
Procedure
6. Results & Data
Analysis
7. Discussion of Results

8. Conclusion
9. Recommendation
10. References

Content Description

Marks Allocated

Refer to respective lab sheets / instructions for title of

experiment.
State the purpose that describes the intention of the
experiment, investigation or accomplishment.
Provide an understanding of the experiment which
includes necessary diagrams, theory and equations.
List equipment, machine, accessories, components,
etc. Shall include brief description of any noble
instrumentation / set-up.
Describe procedures or methods used. Equipment
handling.
Summarize results and present data in tables or
figures. Illustrate trends or comparisons. Show
sample calculation. Answer any questions required.
Discuss what results mean and what conclusions may
be drawn from them. Support results with
understanding of theory. May also include alternative
methods, accuracy, sources of errors, etc.
Summarize the outcome of the experiment based on
the results and analysis. Relate this to the objectives.
Recognize a need for improvement/modification in the
system. Incorporate innovative ideas in the
experimental work or set-up.
List references to methods and related studies in
appropriate style.

Please note:
Include this grading form in your report.

4
6
15
10
15
25

15
5
3
2
Total: 100

Marks Obtained

Assigned Course
Outcomes COs

To Achieve
POs

1.0

TITLE: DESTRUCTIVE TEST BEND TEST & NICK BREAK TEST /

FRACTURE TEST TO EVALUATE QUALIFY OF WELD ON BUTT &
FILLET WELDS

2.0

OBJECTIVES
1. To evaluate quality of weld on Butt & Fillet welds.
2. Determine the toughness and hardness of the material
3. To get exposed with destructive test method

3.0

INTRODUCTION
In a welding field, the characteristic or the welding is measured
through a test which is can be divided into two types, Destructive Test
(DT) and Non-Destructive Test (NDT). The test are apply according on
what characteristic need to be determine such as strength, toughness
and hardness. For this experiment session, a Destructive Test method
will be used in order to get determine the entire characteristic needed.
As the name suggested, a Destructive Test process include method
where the material are need to be broken down to be examined.
In practice it means, for example, finding out if the quality of a weld is
good enough to withstand extreme pressure or to verify the properties
of a material. To get all of those properties, a Non-Destructive Test
method cannot be used other than Destructive Test method as the
specimens of the material must be extracted or the properties cant be
examined. This destructive method is generally the best or suitable
solution and an economic for mass produced objects, as the cost of
destroying a small number of pieces is negligible. Through the result,
we can analyze in which point your material eventually gives up and
cracks and then compared or referred to the regulations and/or quality
guidelines.
Destructive tests are best when used together with our nondestructive methods: this combination gives the best information on
materials and welds. Non-destructive tests show if cracks, corrosion or
4

other faults exist. Destructive tests in turn indicate how and when the
objects are in danger of breaking down or failing. But for this time we
are focusing more on destructive test and examined the material.
Destructive test that will be used are through, Bend Test for Butt Weld
which is Face Band Test (FBT) and Root Band Test (RBT), Nick Break
Test (NBT) for Butt Weld and Fracture Test (FT) for fillet weld.
Bend Test is usually used to examine whether the heat affected zone, as well as the weld
itself did not become brittle during the weld process. The Nick Break Test (NBT) is
useful for determining the internal quality of the weld metal. This test reveals various
internal defects such as slag inclusions, gas pockets, lack of fusion, and oxidized or
burned metal. Fracture Test (FT) for fillet weld is used to find out the weld imperfections
that may harm fillet weld. Defects like porosity, lack of penetration, solid inclusion are
observed on fracture surface of split parts. The benefits of destructive test are welder
able to verify properties of a material, determines quality of welds, helps you to reduce
failures, accidents and costs and ensures compliance with regulations.

4.0

MATERIALS AND TOOLS

1. Specimens
a) Butt weld (for Root Nick Break Test)
b) Butt weld (for Face Nick Break Test)
c) Fillet weld (for Fracture Test)
2. 50 Tons Press Machine

3. Specimens holder for destructive tests

5.0

LABORATORY WORK PROCEDURE

i.

Nick Break Test (NBT) for Butt Weld

1. Two specimens for NBT were prepared.
saw cut of depth 1.5 2.0 mm around center of weld

2. Cyclic / fatigue fracture test s were done by using a 50 tons press machine
for:
a) Face test
b) Root test

3. Internal defects such as porosity, slag inclusion, and etc. were observed and
recorded.
4. With reference to Standard Codes (BS/AWS/ASME), the results were
commented.
ii.

Fracture Test (FT) for Fillet Weld

1. Single Fillet Weld was done on a T-joint.
Throat
T-Joint

Leg length

Leg length
Direction to cause fracture
Saw cut,
depth 1.5 -2.0 mm

2.
3.
4.
5.

The specimen was cut and prepared for FT using disc cutter or power saw.
Leg length and throat were measured.
Weld penetration was observed.
Centre of weld at face was saw cut to a depth of 1.5 2.0 mm.

6. FT was done on the fillet weld by using a 50 tons press machine.

7. The presence of internal defects such as porosity, slag inclusion, lack of root
penetration, lack of root fusion, and etc. were observed and recorded.
8. With reference to Standard Codes (BS/AWS/ASME), the results were
commented.

6.0

RESULTS AND ANALYSIS

i.

Root Bend Test for Butt Weld

ii.

Face Bend Test for Butt Weld

10

iii.

Fracture Test of Fillet Weld

11

7.0

DISCUSSIONS

BEND TEST
Based on the picture in the result section for face bend test, the testing shows that
no defect was found on the face of the weldment. The face bend test conducted was to
verify whether any defect could be found by visual inspection. The face bend test mainly
focus on the visual of the face of the weldment. Face bend test bends the face of the
weldment into plastic deformation in which stretch the area of the face weldment. As the
specimen undergo the testing, the area of the face weldment stretch and that particular
area will be magnify and for this testing the area is the face of the weldment. If any
deformation had occur of the face of the weldment, the defect can be seen with visual
inspection. This is because, any defects such as crack or porosity will be magnify as the
force is applied during the testing was conducted. The force applied will concentrate on
the area of defect as force will tend to concentrate at any stress point on the face of the
weldment. Therefore as no indication was found by the visual inspection done on the
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face of the weldment, it can be concluded that the specimen face of weldment is
acceptable for application as no defect was found during the face bend test conducted.
Based on the picture in the result section for root bend test, the testing shows that there
are indication of defect by the visual inspection done.

The highlighted red box is the result of the visual inspection done to the specimen which undergo
the root bend test. The bend test produced a linear indication on the root of the weldment which
is highlighted in the red box. Another yellow highlighted box shows crack that occurred on the
root of the bend test. Root bend test is the same as face bend test except for the focus area which
is according to the name of the bend test. As the specimen is force to bend, the stress produced
by the bending will focus on any defected area or stress concentrated point in which will lead to
any failure. For this case, linear indication and cracks were visualize on the root area of the
weldment. These type of defects are caused by lack of fusion, wrong weld speed and fast rate of
cooling. The lack of fusion are caused by incorrect amount of voltage used for the welding
process and improper welding technique. Lack of fusion are the main contribution of linear
indication and crack as the weld metal and base metal are not fused together thus, providing an
area of gap which will attract stress concentration inducing failure. Weld speed also contributes
to the lack of fusion as fast welding speed disrupt the melting and fusion of base metal with weld
metal. Rate of cooling is also an important factor as normally welding are done in passes. An
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amount of time must be given for the first pass of the welding to cool before continuing with the
second pass. If the amount of cooling time isnt enough, the heat produced from the first pass
will be trap underneath the second pass. As the outer area of the weldment are cooling and
solidifying, the center of the weldment are still in cooling process and this will lead to uneven
cooling in the weldment area thus inducing crack.
The face bend test and root bend test are done for specimen which have thickness below 12 mm.
The side bend test is done for specimen which have thickness greater than 12 mm. This is
because the face and root bend test is not feasible to be done for specimen thicker than 12 mm as
it will disrupt the visual inspection. Thus by conducting the side bend test the visual inspection
can be done without any interruption by viewing the cross section of the weldment.

14

NICK BREAK TEST

Nick Break Test
Nick break test is useful for determining the internal quality of the weld metal. From
the result we can determine that either the welding process that have being done to connect
the butt joint is good or not. From what we have achieved from the experiment, it shows the
internal defect that occurs in the weld joint as the results that have been spotted. The weld
penetration is not deeper and this is shown by the applied force before the test specimen
break. This is happen because of the welding preparation for the joining process is not really
good or suitable with the type of material or size of material. The joint process need to
change or combine with other type of joint such as bevel joint. This can help reduce the
defect of lack of weld penetration.
Besides that, the other defect that we can see through the result is there some burn
metal that happen at the base metal. This happen because of the over weld or the speed of
travel for the welding torch or the hand of the wielder is to fast or not constant. We can
reduce this defect by changing the welding process that is by using robotic machine or other
weld machine that can control the speed travel of the weld bid. The corrosion also occurs in
the break structure. This is because of the oxidation and to avoid that, the test specimen
should be test immediately after been prepared. The other effect is the slag that not been
removed after the weld run and this will result gas pocket and porosity. To avoid that, the slag
should be removed after every weld.

15

FRACTURE TEST

Fracture tests are conducted to qualify a welder by the examination of fracture surfaces of a
weld metal rather than using expensive macroscopic examination. The procedure is applied in
order to assess the quality of test weld made by a welder. Although the standards elucidate the
test procedure, test location, technique, dimensions and type of specimen. Fracture is made to
find out the weld imperfections that may harm fillet weld. Defects like porosity, lack of
penetration, solid inclusion are observed on fracture surface of split parts. The results also
showed that the fracture occur on the base metal and not on the weld metal. It means that the
ductility of the base metal is lower than the weld metal.
The result showed toward the T-joint fillet weld by using fracture test did not seen any defect
on the weld bead. The surface on the weld bead clears from defect. The fracture test as
referred to America Standard Mechanical Engineering is ASTM E1820 11. However, there
were others defect which not state before commonly occurred in welding such as porosity and
incomplete penetration.
Other defect will define is porosity results when the gases are entrapped in the solidifying
weld metal. These gases are generated from the flux or coating constituents of the electrode
or shielding gases used during welding or from absorbed moisture in the coating. Rust, dust,
oil and grease present on the surface of work pieces or on electrodes are also source of gases
during welding.
There are several types of porosity which are uniformly scattered porosity, cluster porosity,
linear porosity and piping porosity or wormhole. Uniformly scattered porosity is porosity
uniformly distributed throughout single pass weld or throughout several passes of a multi
pass weld. It is caused by faulty welding technique, faulty material or consumable or joint
16

preparation that lead to gas formation or entrapment. Cluster porosity is a localized grouping
of pores and cause by improper initiation or termination of welding arc or loss of shielding.
Linear porosity aligned along a joint boundary, the root of weld or an interbead boundary.
The cause is by contamination that lead to gas evolution along a particular boundary. Piping
porosity or wormhole elongated gas discontinuities or tubular cavity formed by entrapped gas
during solidification of molten metal. Usually does not extend to surface, but when one or
two are seen on the surface of weld, often revealed several subsurface piping porosities
interspersed among the exposed pores.
Plus, other defect is incomplete penetration. There are 3 types of defect is found in any of
three ways. Welding current has the greatest effect on penetration. Incomplete penetration is
usually caused by the use of too low a welding current and can be eliminated by simply
increasing the amperage. Other causes can be the use of too slow a travel speed and an
incorrect torch angle.

17

8.0

CONCLUSION
The bending test conducted were able to evaluate the quality of the specimen for butt
weld joint and fillet weld joint. The toughness and hardness of the material were able to
be determined. Furthermore, the students had been exposed to the destructive testing
method of face and root bend test, nick bend test and fracture testing. As a conclusion
the objectives set for this experiment had been achieved.

18

9.0

RECOMMENDATION

BEND TEST
For the face and root bend test session:
1. Conducting the side bend test will help the students in understanding more on the
practical of the bend test.
2. Conducting the test using more specimen which shows the defect and non-defect
during the bend test.

NICK BREAK TEST

For this kind of test, the student should see more about the preparation of the welding
specimen to know more about the process that have being done to the welding specimen so
that the student can detect and determine the cause or the reason why the defect in the result
is happen or shown. The students also need to be complete briefing or explanation about the
specimen for the weld that will be used for this experiment so that the students can
understand more about the experiment that will be done.

FRACTURE TEST
Size of the fillet weld should be suitable with the thickness of the plate. It is to avoid wastage
and can cause more economical. Parts to be considered in choosing size of the fillet welds
are:

Throat- The minimum dimension of throat thickness used for purposes of design. Also

known as effective throat thickness.

Leg length- The distance from the actual or projected intersection of the fusion faces
and the toe of a fillet weld, measured across the fusion face.

19

10.0 REFERENCES
1. Brian Smith (2014), Welding Practice, Routledge
2. Hoobasar Rampaul (2003), Pipe Welding Procedures, Industrial Press Inc
3. R Singh (2008), Weld Cracking in Ferrous Alloys, Elsevier

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