Application of Digital Image Correlation in Cross Weld Tensile Testing: Test Method Validation

This study addresses the limitations of cross weld tensile testing (CWTT) in quantifying local mechanical properties across microstructural and compositional gradients in dissimilar and matching filler metal welds. A digital image correlation (DIC) methodology was validated for application in CWTT by direct comparison of stress-strain curves generated using conventional and virtual DIC extensometers in tensile testing of homogeneous steel samples. DIC-instrumented CWTT of dissimilar weld metal Alloy 625 filler metal on F65 steel demonstrated capability in quantifying the local yield strength, strain-hardening kinetics, and strain at failure in the base metal, heat-affected zone (HAZ), fusion boundary (FB) region, and weld metal in dissimilar and matching filler metal welds. It was shown that the high strain -hardening capacity in Alloy 625 weld metal led to base metal failure in CWTT despite the lower Alloy 625 weld metal yield strength. It was also shown that DIC-instrumented CWTT can be used for determining weld metal undermatching and overmatching conditions in compositionally matching- and dissimilar-metal welds. Furthermore, by quantifying local strain distribution (both elastic and plastic) in the HAZ, FB region, and weld metal, DIC-instrumented CWTT provides an additional method for evaluating hydrogen-assisted cracking susceptibility in dissimilar-metal welds.