1 AS 2205.5.

1—2003
TM
Australian Standard
AS 2205.5.1

Methods for destructive testing of welds in metal

Method 5.1: Macro metallographic test for cross-
section examination

PREFACE
This Standard was prepared by the Standards Australia Committee WD-006, Testing of
Welds, to supersede AS 2205.5.1—1997.
The objective of this edition is to update the Standard and include editorial changes in
accordance with current Standards Australia editorial policy.
The term ‘informative’ has been used in this Standard to define the application of the
appendix to which it applies. An ‘informative’ appendix is only for information and
guidance.
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

METHOD

1 SCOPE
This Standard sets out a method for macro testing of a welded joint. The test reveals the
weld shape, the extent of penetration and the soundness of the welded joint.

2 REFERENCED DOCUMENTS
The following documents are referred to in this Standard:
AS
1863 Coated abrasives (technical products)
2205 Methods for destructive testing of welds in metal
2205.1 Method 1: General requirements for tests
2205.6.1 Method 6.1: Weld joint hardness test
2243 Safety in laboratories
2243.1 Part 1: General
2243.2 Part 2: Chemical aspects

3 PRINCIPLE
A cross-section of a welded joint is prepared in a specified manner and examined visually.

4 PREPARATION OF TEST SPECIMEN

The test specimen shall be prepared in accordance with the requirements of AS 2205.1 and
the following:
(a) The test specimen shall be detached from the weld zone as specified in the relevant
application Standard to the dimensions indicated in Figure 1.
© Standards Australia
 AS 2205.5.1—2003 2

(b) The test specimen shall be prepared, polished and etched, using an approved method
and etching solution (see Appendix A for details of an approved method and
recommended etchants).

5 PROCEDURE
The test specimen shall be examined visually. If necessary, this may be done with the aid of
magnifying equipment.
NOTE: In some cases, imperfections may be better observed before the etching solution is
applied.

6 REPORTING OF RESULTS
The test results shall be reported as follows:
(a) Identification of this and any relevant application Standards (i.e., ‘AS 2205.5.1,
Macro metallographic test for cross-section examination and ............’).
(b) Identification of test specimens by any markings (e.g., ‘Specimen A’).
(c) Type of material and, if known, Standard number and grade.
(d) Any special features of test specimen before testing (e.g., any visible imperfection).
(e) Location of weld zone from which test specimen was cut.
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

(f) Etchant used.

(g) Appearance of etched surface including presence and type of imperfections.
(h) Illustration of the etched surface (i.e., sketch, photograph, digital or scanned image).

NOTE: This Figure is merely schematic. The test may be applied to other weld configurations and test specimen
thicknesses.

FIGURE 1 TEST SPECIMEN

 Standards Australia www.standards.com.au

 3 AS 2205.5.1—2003

APPENDIX A
MACRO-ETCHING
(Informative)

A1 PREPARATION OF SURFACE FOR ETCHING

The initial preparation of a cut surface may be by milling, grinding, turning or alternatively
by filing, using successively finer files until a satisfactory surface finish is obtained. The
machined or smooth-filed surface is then abraded on successively finer grades of
waterproof silicon carbide paper (see AS 1863). A suitable sequence of grit sizes is
100 grit, P240, P600 and P1200.
If the specimen is of a suitable size to be conveniently handled, the most satisfactory
procedure is to lay the appropriate sheet of abrasive paper face up on a flat surface (e.g.,
plate glass). The abrasive paper is then lubricated with water, kerosene or other suitable
lubricant and the specimen carefully abraded against it, using a unilinear motion and
applying moderate pressure until all surface indications from the previous treatment have
been removed. The specimen is then washed to remove all traces of abrasive and the
procedure repeated with the next finer grade of abrasive paper. The direction of abrading in
each case should be at right angles to the marks made by the previous paper.
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

In cases where large quantities of suitably sized samples may require preparation, automatic
or semi-automatic machines may be suitable for fine grinding. Samples are mounted in
specimen holders to facilitate multiple preparation and introduced face down on to the
grinding disc of the machine. Pressure and time can be preset and grinding continued until
all traces of previous surface preparation have been removed. Successively finer papers are
used (see AS 1863) until a suitable finish is achieved.
In situations where the specimen size is such that none of the above procedures are
convenient, preparation may be carried out by employing rotating abrasive discs or
finishing belts of successively finer grit sizes. Care should be taken to avoid undue pressure
on the surface and overheating. Undue pressure will cause metal to flow over and obscure
fine imperfections that may be present. Overheating may arise with high-speed dry abrasion
and give spurious effects on the etched surface.
A fine-machined surface, produced by sharp tools with adequate lubrication or a surface
abraded to P600, may be suitable for macro-etching without further preparation. Such
machined surfaces are not, however, in the most suitable condition for the detection of fine
porosity, for which purpose it is recommended that abrading down to P1200 grade paper
should be employed. In situations that require a high quality finish for the detection of fine
cracks and similar imperfections, it is recommended that lapping be undertaken on discs
using appropriate diamond grades (e.g., 12 µm, 9 µm, 6 µm).
For thermally cut surfaces, care should be taken to remove the whole of the metal that has
been affected as a result of the temperature attained in the thermal cutting operation.
Surfaces will etch more readily and evenly if any dirt, oil or grease is removed with a
suitable solvent.

A2 ETCHING PROCEDURES
Etching is carried out, either by swabbing the surface with cotton wool held by tongs or
glass rod or by immersion of the specimen in the etchant, until good definition of the
structure is obtained. After etching, the surface should be washed thoroughly in water, then
rinsed in alcohol (ethanol or methanol) and dried as quickly as possible, preferably with a
hot air blast. Care should be taken to choose a form of alcohol that does not leave an

www.standards.com.au  Standards Australia

 AS 2205.5.1—2003 4

unwanted residue. A permanent preservation may be obtained by coating the surface with a
thin clear lacquer.
Etchants should be used at ambient temperature, except for sodium hydroxide solution,
which should be warmed to approximately 60°C.

A3 ETCHANTS
A3.1 Safety precautions
The preparation of etchants involves the handling of potentially dangerous substances.
Consequently, they should only be prepared by or under the guidance of experienced people
using the appropriate safety equipment. Persons using the etchants must likewise be aware
of the correct method of use and the potential hazards of misuse. Guidance on the safe
handling of chemicals in laboratories is given in AS 2243.1 and AS 2243.2.
A3.2 Carbon and low alloy steel
A3.2.1 Nitric acid in water
Add 25 mL of nitric acid to 75 mL of water. This etchant is useful where special facilities
are not available.
CAUTION: ALWAYS POUR THE ACID INTO THE WATER. NITRIC ACID
CAUSES BAD STAINS AND SEVERE BURNS.
A3.2.2 Nitric acid in alcohol (10% nital)
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

Add 10 mL of nitric acid to 90 mL alcohol (ethanol or methylated spirit).

CAUTION: GREAT CARE MUST BE EXERCIZED IN THE PREPARATION OF
THIS SOLUTION, AS THE MIXING OF CONCENTRATED NITRIC ACID AND
ALCOHOL CAN BE EXTREMELY DANGEROUS. THE ACID SHOULD BE
ADDED SLOWLY TO THE ALCOHOL WHILE THE MIXTURE IS BEING
CONSTANTLY STIRRED. ALTHOUGH THIS IS MAINLY A LABORATORY
ETCHANT, IT MAY BE USED ELSEWHERE, PROVIDED THAT CARE IS TAKEN
CONCERNING ITS MIXING, ITS FLAMMABILITY AND ITS TENDENCY TO
DECOMPOSE SLOWLY.
A3.2.3 Nitric acid in alcohol (2% nital)
Add 2 mL of nitric acid to 98 mL of alcohol (ethanol or methylated spirit).
NOTE: This etchant is particularly recommended for weld joint hardness testing (see
AS 2205.6.1).
A3.2.4 Ammonium persulfate in water
Add 10 g of ammonium persulfate to 90 mL water. This etchant is relatively safe to handle,
but must always be used freshly prepared. It requires a good surface finish and has a
tendency to reveal segregation, which can sometimes mask weld features.
A3.3 Austenitic steels
CAUTION: THE ACIDS USED FOR ETCHING AUSTENITIC STEELS ARE
EXTREMELY CORROSIVE AND CARE SHOULD BE EXERCISED IN MIXING
AND USE.
A3.3.1 Chrome regia solution
Add 5 g of chromium trioxide (chromic acid) to 50 mL of water followed by 25 mL of
hydrochloric acid.

 Standards Australia www.standards.com.au

 5 AS 2205.5.1—2003

A3.3.2 Nitric acid/hydrochloric acid solution

Add 30 mL of nitric acid* to 30 mL of water followed by 40 mL of hydrochloric acid†.
A3.3.3 Ferric chloride
Add 10 g of ferric chloride to 120 mL of water followed by 30 mL of hydrochloric acid.
A3.4 Aluminium and aluminium alloys
A3.4.1 Tucker’s reagent
Add 10 mL of nitric acid* to 25 mL of water followed by 45 mL of hydrochloric acid† and
15 mL of hydrofluoric acid (40%).
CAUTION: HYDROFLUORIC ACID IS EXTREMELY DANGEROUS AND, EVEN
WHEN VERY DILUTE, MUST NOT COME IN CONTACT WITH SKIN OR
FINGERNAILS.
A3.4.2 Sodium hydroxide
Add 10 g of sodium hydroxide to 100 mL of water and etch at approximately 60°C.
NOTE: After etching with sodium hydroxide solution, clean surface by dipping in dilute (20%)
nitric acid*.
A3.4.3 Cupric chloride
Add 10 g to 20 g of cupric chloride to 120 mL of water. Swab the surface with cotton wool
for between 30 s and 45 s. The intensity of the etch is checked by periodically by swabbing
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

away the heavy dark brown deposit that is formed. The last traces of the deposit are
dissolved by swabbing or by immersion in concentrated nitric acid*.
A3.5 Copper and copper alloys
A3.5.1 Ferric chloride
Add 10 g of ferric chloride to 120 mL of water followed by 30 mL of hydrochloric acid†.
A3.5.2 Nitric acid†
Add up to 30 mL of nitric acid to 70 mL of water.
CAUTION: PRECAUTIONS SHOULD BE TAKEN TO AVOID INHALATION OF
THE TOXIC BROWN FUMES, WHICH CONSIST OF OXIDES OF NITROGEN,
AND ARE EVOLVED DURING ETCHING.
A3.5.3 Ammonium persulfate
Ammonium persulfate may also be used when added to water as described in
Paragraph A3.2.4.

* ρ 1420 kg/m 3
† ρ 1160 kg/m 3

www.standards.com.au  Standards Australia

Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

AS 2205.5.1—2003
6

NOTES
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

NOTES
AS 2205.5.1—2003
 AS 2205.5.1—2003 8

This Australian Standard was prepared by Committee WD-006, Testing of Welds. It was approved on behalf of the Council of Standards
Australia on 21 March 2003 and published on 15 April 2003.

The following are represented on Committee WD-006:

Australian Railway Association
AUSTROADS
Bureau of Steel Manufacturers of Australia
National Association of Testing Authorities Australia
Welding Technology Institute of Australia
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

Keeping Standards up-to-date

Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are
periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It
is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been
published since the Standard was purchased.
Detailed information about Standards can be found by visiting the Standards Australia web site at www.standards.com.au and looking up
the relevant Standard in the on-line catalogue.
Alternatively, the printed Catalogue provides information current at 1 January each year, and the monthly magazine, The Australian
Standard, has a full listing of revisions and amendments published each month.
We also welcome suggestions for the improvement in our Standards, and especially encourage readers to notify us immediately of any
apparent inaccuracies or ambiguities. Contact us via email at mail@standards.com.au, or write to the Chief Executive, Standards Australia
International Ltd, GPO Box 5420, Sydney, NSW 2001.

Originated as AS B301.7—1971.
Previous edition A 2205.5.1—1997.
Fourth edition 2003.

This Standard was issued in draft form for comment as DR 02630.

COPYRIGHT
© Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic
or mechanical, including photocopying, without the written permission of the publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 5175 X Printed in Australia
Accessed by TAFE NSW (TAFE Library Services) on 22 Jun 2016 (Document currency not guaranteed when printed)

This page has been left intentionally blank.