destructive testing Metallurgical services

ARIES Mechanical Testing & Metallurgical Lab, providing wide range of Destructive testing’s & Metallurgical services to the Oil & Gas, Marine & Industrial sectors.

Aries Testing lab is well equipped with advanced testing equipment’s & in-house machine shop to conduct the testing as per ASTM, BS, BS EN, DIN, ISO or client/project specified standards with ultimate customer satisfaction.

ARIES Material Testing Lab is accredited by the latest ISO/IEC 17025:2017 from ENAS, Abu Dhabi (Range & scope, refer the latest certificates) Aries metallurgical team providing worldwide services in Consulting, Onsite Testing & Failure investigations through our branch offices and experts. We are well-equipped and experienced in Plant shutdowns & Asset integrity analysis. We do onsite replica metallography analysis on Boilers, Pressure vessels, Power generators, Marine engine, Critical plant equipment’s, Pipelines & Welded joints.

It's necessary to test in a Lab and measure the mechanical properties of engineering material before their intended application to elude unacceptable levels of failure or deformation. Laboratory testing determining the properties such as tensile characteristic, hardness, impact toughness, ductile to brittle temperature. Testing under various conditions are necessary for engineering & design applications. The results of Laboratory testing will reflect the material behaviour in ideal conditions.

We ascertain the mechanical properties with carefully designed laboratory test methods, data analysis and experienced personal’s interpretation.

ARIES Material Testing Lab is accredited by the latest ISO/IEC 17025:2017 from ENAS, Abu Dhabi (Range & scope, refer the latest certificates)

Aries mechanical testing lab is using standard test method to identify the basic properties of the materials like, yield point & elongation under uniaxial tensile load. This test will help to understand exact value of Yield Strength, Tensile Strength, % Elongation and reduction area of the material. Aries Testing Lab using Computerized Universal Testing machine to determine the mechanical properties of various ferrous and nonferrous metals .This value used to interpolate behavior of material during various type load condition.

  •  Uniaxial tensile testing
  •  Proof strength analysis for bolt.
  •  Full size tensile testing .
  •  Room and high temperature tensile testing.
  •  Tensile test for Plate, Pipe, Tube, Welded Sample

Testing Lab used to evaluate both the ductility and soundness of a material. It is often used as a quality control test for butt-welded joints, having the advantage of simplicity of both test piece and equipment. Aries Testing Lab using different bend re bend mandrill according to the standards and project specifications.

  •  Weld metal testing- Rebend / root / face / side bend test.
  •  Compression test.

In laboratory testing, Impact test validate the ability of material withstand during impact or sudden changes in load, it also help to find ductile to brittle transition temperature of the material, this will help to identify the materials behavior in low temperature application. Aries testing lab having the capacity to conduct the test from room temperature to various sub-zero temperature.

  •  Subzero temperature.
  •  Room temperature.

Aries Testing Lab using calibrated benchtop hardness testers to measure accurately the material’s resistance to localized plastic deformation..

  •  Rockwell Hardness Testing.
  •  Vickers Hardness Testing.
  •  Brinell Hardness Testing.
  •  Onsite hardness measurement.

Chemical Composition Analysis OES

Industries demand advanced elemental analysis of various metals importing from world wide manufactures and suppliers.The final inspection of products and quality is a main concern for most of the manufacturing , Marine , Oil & gas indstries.The reliability of resuts are critical for the success. Inconsistent analysis leads to expensive reworks. OES is the most trusted and widely used method for creation and verificaiton of mill testing reports worldwide.

ARIES using world leading Lab based Optical emisssion Spectro Equipments (OES) to analyze the different base materials. The latest laborotory analyzer from SPECTROMAXx & Mobile Optical Emission reveals the full chemistry of critical alloy elements at low detection limits.

The detection limits include Carbon (0.001) Phosphorus(0.0005), Sulfur (0.0002), Molybdenum (0.001) Nickel (0.0015) Chromium:(0.0005) Silicon (0.005) Nitrogen (0.001) etc. Our various base calibrations are capable to satisfy the test requirments of API 5L testing, API RP 578,ASME Section IX B & PV,ISO 17025 standards.

We use Portable Spectro analyzers at various sites for unknown material identification , Carbon steel metal identificaiton , SS grades 301 L , 304 L ,316 L, , 410 , 410 S material confirmation, complex shape analysis , welding consumables analysis, Oil field fittings & flanges analysis..etc

Metallurgical Testing deals with microscopic level of examination of a material (i.e., metal or alloy). It includes a collection of examinations and interpretations to verify a materials parent form and analysis of any changes to this form that crumble the properties of a particular metal or component. The microscopic evaluation provides vital details about the microstructure, structure inhomogeneity and defects such as cracks, voids.

Our metallurgical lab specialists offer wide range of testing methods including complex onsite inspection and laboratory-based analysis. We are equipped with latest advanced inspection equipment that provides and acquires data on a nano scale range (approx.50Kx magnified). This could help the customers & clients with accurate and precise interpretation of results as per their requirement.

We are specialized in the fields of Micro analysis, Advanced metallurgical analysis (Scanning Electron Microscopy), Fractography, Replica Metallography, Corrosion study & Corrosion Control, Case Studies & Investigations, Failure analysis of material & components, Fracture mechanism of materials (fatigue, creep, wear deformation). Contamination and trace element analysis.

We offer detailed Metallurgical Testing & failure investigation that help in finding out the root cause of material failure. Our range of services includes:

  •  Microstructure
  •  Macrostructure
  •  SEM -EDX (Scanning Electron Microscopy)
  •  Grain Size Measurement
  •  Ferrite count
  •  Weld characteristics
  •  Depth Penetration
  •  Fusion Zone Size & number of passes
  •  Carburization & Decarburization
  •  Identification of ferrite & Sigma phases
  •  Nitride Case depth
  •  Heat Treatment Evaluation
  •  Case depth & Coating thickness measurement
  •  Nodularity & Nodule Content
  •  Linear Measurement
  •  Grain Flow & Surface Condition
  •  Intergranular Corrosion
  •  Intergranular attack & oxidation
  •  Carbide precipitation
  •  Sensitization
  •  Residual stress measurement

We Aries, extends our services in Corrosion testing focusing to provide our clients with early detection of corrosion and minimizing the failures in materials that are subjected to face corrosion. It’s a challenging scenario in many industries especially in oil and gas fields that are caused by corrosion effects. It’s an apt option to test these materials before that are being installed. So we would like to recommend Corrosion testing and proper evaluation by our team as per recognized standards.

The metal and alloys are made up of grain, in micro level the structure is separated by grain boundary. Intergranular corrosion is preferential attacks on the grain boundary where grain remain largely unaffected. This type corrosion occurred due to segregation of impurity (precipitation of nitrides, carbides, and other intermetallic phases, such as sigma phase) on the grain boundary. Such precipitation can produce zones of reduced corrosion resistance in the immediate vicinity.

This mainly occurs with incorrect heat treatment service, materials are liable to crack or fail by intergranular corrosion (IGC) much more rapidly than properly treated materials. In any case the mechanical properties of the structure will be seriously affected. Aries can carry out testing as per ASTM A262, ASTM A923, ISO 3651 and ASTMG28 standards.

During services if the material exhibits localized pits or gaps on its surface, pitting or crevice corrosion may be the culprit. Pitting corrosion is characterized localizes pit holes, and crevice corrosion occurs where two materials meet. Material resistance to pitting and crevice should be assessed before its usage. Aries provide pitting and corrosion test based on ASTM G48 .

Aries laboratory is fully equipped with latest methods of testing in compromise with relevant standards of testing. We perform Sulphide Stress Cracking (SSC) testing of metals subject to cracking with simultaneous effect of tensile stress and corrosion in the presence of wet media and H2S environment as per NACE TM 0177 standard.

As per this test, the metals are subjected to tensile stresses for resistance to cracking failure in low-pH aqueous environments containing hydrogen sulphide (H2S).This type of corrosion is hazardous and often unpredictable so its suggested to have proper inspection of your materials to ensure quality and endurance.

We performs and evaluate carbon steel, low alloy steel and corrosion resistant alloys for sour service applications as per,NACE TM 0177 standard methods: Tensile Test, Bent-Beam Test & Ring Test. We execute Hydrogen Induced Cracking (HIC) testing to evaluate the susceptibility of low alloy steel and carbon steel to hydrogen embrittlement. Hydrogen Induced Cracking (HIC) testing is recommended to evaluate the resistance of pipeline and other materials to hydrogen induced cracking corrosion caused by hydrogen absorption from aqueous sulphide corrosion. The test is duly performed in accordance with NACE TM0284-2011. After the test the specimens are evaluated, examined microscopically and cracks if present, are reported and their ratios CSR (Crack Sensitivity Ratio), CLR (Crack Length Ratio), CTR (Crack Thickness Ratio) are calculated.

Heat treatment is carried out to alter the mechanical and physical property of the metals. The controlled heating and cooling of metals allows us to achieve desired mechanical property. Heat treatment is also carried out due to manufacture process such as welding, hot forming etc. to regain its material property.
Aries can help to develop heat treatment cycle to achieve desired property of material with precise heating and temperature control. We are helping to develop in heat treatment cycle such as solution annealing, quenching, tempering etc.

Residual Stress Residual Stress

Residual stresses are as those stresses that remain in a body after removing the external load. These stresses influence the behaviour of mechanical components and can affect their structural and dimensional stability as well as the fatigue and fracture resistance of the materials. A residual tensile stress actually facilitates crack propagation and therefore reduces the fatigue life of a mechanical component. Residual stresses limit the loading capacity and safety of mechanical components during operation and in certain conditions it is necessary to know the quantity of those stresses.

Virtually all manufacturing and fabricating processes — casting, welding, machining, moulding, heat treatment, etc. introduce residual stresses into the manufactured object. Another common cause of residual stress is in-service repair or modification. In some instances, stress may also be induced later in the life of the structure by installation or assembly procedures, by occasional overloads, by ground settlement effects on underground structures, or by dead loads which may ultimately become an integral part of the structure.

Sometimes alone and some-times in combination with other factors, unaccounted for residual stresses have caused the failure of major bridges, aircraft, ships and numerous smaller structures and devices, often with substantial loss of life. At other times, residual stresses are deliberately introduced to provide beneficial effects, such as in pre-stressed concrete, shot-peening and cold hole-expansion.

Aries have the capability to quantify the residual stress using non-destructive portable equipment. On site field measurement and laboratory-based measurement also can be carried out using this NDT method.

Residusl Stress on Wheels

The presence of high residual stress in Railway wheels & Crane wheels are the main causes of cracks that may result in severe issues during the wheel’s services life.The Railway industry and other vehicle industries is required to ensure that stress levels present in wheels are with acceptable limits defined by the category of the wheel under study. A premature diagonosis can prevent dangerous and costly situation. We are using EMAT technology as a solution for measurement of residual stress in wheels by a reliable easy and fast method.

EMAT (Electro Magnetic Acoustic Transducer) Technology is weidely used in multiple applications

  •  Its capable of generating ultrasound directly within the material under inspection
  •  Dry Inspection, No Couplant is required
  •  Inspection through painting and coating
  •  No surface preperation is required
  •  Unique wave modes
What Causes Residual Stress?
  •  Residual stress can be induced due to welding
  •  Residual stress can be developed on structure component in service
  •  Manufacturing and fabrication process introduce residual stress (Casting, Molding, Machining, Plastic deformation by Bending, Rolling, Forging, Wheels, Pressure vessels, Oil Tanks etc)
  •  Estimation of stress created by heat treatment process
  •  Stress measurement from in-service pipeline
  •  Residual stress could be caused by localized yielding of the material , due to sharp notch or certain surface treatments like shot peening or surface hardening
  •  Failure analysis of component.
  •  Thermal residual stresses are created due to differential expansion when a material is heated or cooled
  •  When any object is formed through cold working , there is the possibility to develop residual stress
What residual stresses can cause
  •  Residual stresses can result in visible distortion of a component and lead to a failure
  •  Residual stresses can cause a metal part to suddenly split into two or more pieces after it has been resting on a floor without external load being applied
  •  Residual stresses relaxation can deform a piece when it is in machining
Residual stress measurement
  •  Stress due to external loads can be calculated with a degree of accuracy, but residual stresses are difficult to foresee. Therefor it is important to have a reliable method able to measure directly with minimum damage to the surface
  •  Residual stresses can play an important role in explaining and preventing failure of a component
  •  Residual stresses relaxation can deform a piece when it is in machining
  •  ARIES use ultrasonic portable equipment to measure the Residual stress from a component without any destruction of the material

Fracture_testing

All the material has inherent flows, the criticality of this flows needed to be determined during Design and in services stages. Conventional design procedures are based upon the yield strength or ultimate tensile strength. This approach was considered to be relatively safe when appropriate safety factors were used. Instances where unstable fracture occurred at stresses below the yield stress however necessitated making provision for such circumstances. To understand and prevent these fracture and failure there need to know the fracture mechanics of the material.

Fracture mechanics can be used in three major areas:

  •  Design
  •  Material selection and alloy development
  •  Determining the significance of defects

Fracture toughness measurement is one of the fundamental steps for studying the fracture mechanism of material.

The Fracture toughness test is to measure the resistance of a material to the presence of a flaw in terms of the load required to cause brittle or ductile crack extension (or to reach a maximum load condition) in a standard specimen containing a fatigue pre-crack. The result is expressed in terms of toughness parameters such as KIc, critical J or critical CTOD. Standards test methods are BS 7448,ASTM E399 ASTM E1820 etc.

Aries have advanced testing equipment to measure the fracture toughness of the material that help to provide critical determination about the fitness, life determination and criticality of flaws in the metallic materials. Since we have both capabilities to provide material testing and fracture mechanics testing, we can provide you with the best material testing programs to increase the quality and confidence in the application.

There are different type of configuration. Most commonly used are Compact Tension (CT), Single-Edge Notched Bend (SENB or three-point bend. Also depends upon the requirement different orientation of specimen need to be prepared.

CTOD TESTING
CTOD

The Crack Tip Opening Displacement or CTOD Test measures the resistance of a material to the propagation of a crack. CTOD is used on materials that can show some plastic deformation before failure occurs causing the tip to stretch open. Accurate measurement of this displacement is one of the essentials of the test. Test standards are BS ISO 12135, BS 7448 and ASTM E1820

KIc TESTING

The property KIc determined by this test method characterizes the resistance of a material to fracture in a neutral environment in the presence of a sharp crack under essentially linear-elastic stress and severe tensile constraint, such as (1) the state of stress near the crack front approaches triaxial plane strain, and (2) the crack-tip plastic zone is small compared to the crack size, specimen thickness, and ligament ahead of the crack. KIc determination done as per ASTM E399 and ASTM E1820

When a material behaves in a linear elastic manner prior to failure, such that the plastic zone is small compared to the specimen dimensions, a critical value of the Mode 1 stress-intensity factor KIc may be an appropriate fracture parameter. The first standardized test method for KIc testing, ASTM E 399

J TESTING OF METAL

J tests: the basic procedure and the resistance curve procedure. The basic procedure entails monotonically loading the specimen to failure or to a particular displacement, depending on the material behavior. The resistance curve procedure requires that the crack growth be monitored during the test. The J integral is calculated incrementally in the resistance curve procedure. The basic procedure can be used to measure J at fracture instability or near the onset of ductile crack extension. The latter toughness value is designated by the symbol JIc.