Mock-Up Testing

Subodh Material Technologists provides mock-up weld testing and evaluation for applicable welding qualification and fabrication requirements.

Our mock-up testing services support evaluation of welded mock-up assemblies, including visual examination, liquid penetrant examination and macro-examination according to applicable requirements.

Mock-up testing is particularly important where the actual weld configuration, joint geometry, accessibility, tube-to-tubesheet arrangement or fabrication conditions need to be evaluated before or during production.

What is Mock-Up Testing?

Mock-up testing involves creating and evaluating a representative welded assembly that simulates the actual production configuration or a specified qualification arrangement.

Mock-ups can be used to evaluate:

• Weld configuration

• Weld quality

• Fusion characteristics

• Weld penetration

• Heat affected zone

• Cracking

• Porosity

• Leak-path dimensions

• Tube-to-tubesheet weld characteristics

• Fabrication and welding practices

The applicable examination and acceptance criteria depend on the governing code, design requirements and project specification.

ASME Section IX Mock-Up Testing

Subodh Material Technologists performs applicable mock-up testing associated with ASME Section IX welding qualification requirements.

The testing program can include the examination methods specified for the particular mock-up configuration.

Typical examinations include:

Visual Examination

Accessible weld surfaces are visually examined for conditions such as:

• Surface cracks

• Porosity indications

• Incomplete fusion

• Burn-through

• Other visible weld discontinuities

Visual examination is performed according to the applicable acceptance requirements.

Liquid Penetrant Examination

Liquid penetrant testing can be used to detect surface-breaking discontinuities that may not be readily visible during visual examination.

For applicable mock-up welds, liquid penetrant examination is performed according to the relevant requirements of the applicable code and examination procedure.

The examination can help identify:

• Surface cracks

• Linear indications

• Surface-connected porosity

• Other relevant surface discontinuities

Macro-Examination of Mock-Up Welds

Macro-examination is an important part of mock-up weld evaluation.

The mock-up weld is sectioned through the required location and the exposed surfaces are prepared and etched to reveal the weld profile and surrounding material.

Macro-examination can evaluate:

• Weld fusion

• Weld penetration

• Weld profile

• Heat affected zone

• Cracking

• Internal discontinuities

• Fusion between weld deposit and tube or tubesheet

• Required leak-path dimensions where applicable

For the applicable ASME Section IX mock-up requirement, the exposed cross-section may be examined at approximately 10X to 20X magnification to evaluate the weld and heat affected zone.

Tube-to-Tubesheet Mock-Up Testing

Mock-up testing is particularly relevant for tube-to-tubesheet welding applications, where the weld configuration and fusion characteristics must be evaluated.

Depending on the design and applicable requirements, examination may evaluate:

• Tube-to-tubesheet fusion

• Weld penetration

• Weld profile

• Heat affected zone

• Cracking

• Required leak-path dimensions

• Weld continuity

This type of evaluation can be important for critical heat exchanger and pressure-equipment applications.

Mock-Up Weld Examination

A typical mock-up evaluation may involve a combination of:

Visual Examination → Liquid Penetrant Examination → Sectioning → Macro Preparation → Etching → Macro Evaluation

The exact sequence and examination requirements depend on the applicable qualification procedure and project specification.

Applications of Mock-Up Testing

Mock-up testing can support qualification and evaluation requirements for:

• Heat exchangers

• Boilers

• Pressure vessels

• Tube-to-tubesheet welds

• Pressure equipment

• Process equipment

• Petrochemical equipment

• Oil & Gas equipment

• Power plant equipment

• Critical welded assemblies

• Specialized fabrication applications

Mock-Up Testing & Metallographic Evaluation

Macro-examination of the mock-up provides a cross-sectional view of the welded joint and can reveal important metallurgical and fabrication characteristics.

The examination can identify:

• Fusion quality

• Weld geometry

• Penetration

• Heat affected zone

• Cracks

• Weld discontinuities

• Interface characteristics

Where required, further metallographic evaluation can complement the mock-up testing program.

Why Choose Subodh Material Technologists?

NABL Accredited Laboratory

Subodh Material Technologists operates as a NABL accredited laboratory as per ISO/IEC 17025:2017, Certificate TC-8225.

Specialized Weld Testing

Our laboratory provides specialized testing and evaluation of welded joints, welding coupons and mock-up assemblies.

Integrated Metallurgical Testing

Mock-up evaluation can be supported by our wider capabilities in:

• Mechanical testing

• Hardness testing

• Microhardness testing

• Metallography

• Chemical analysis

• Corrosion testing

• Fracture and fatigue testing

Technical Evaluation

Testing and examination are performed according to the applicable test method, qualification requirement and agreed project specification.

Related Welding Testing Services

Explore our related services:

• Welder Qualification & PQR Testing

• Welding Consumable Qualification

• Tensile Testing

• Charpy Impact Testing

• Hardness Testing

• Microhardness Testing

• Metallography

• Corrosion Testing

• Chemical Analysis

• Fracture Mechanics

• Fatigue Testing

Frequently Asked Questions

What is mock-up testing?

Mock-up testing evaluates a representative welded assembly to determine whether the weld configuration, quality and other specified characteristics meet applicable qualification or project requirements.

What tests are performed on mock-up welds?

Depending on the applicable requirements, testing may include visual examination, liquid penetrant examination and macro-examination.

Do you perform ASME Section IX mock-up testing?

Yes. Subodh Material Technologists performs applicable mock-up weld testing associated with ASME Section IX requirements.

What is macro-examination of a mock-up weld?

Macro-examination involves sectioning, preparing and etching a welded cross-section so that weld fusion, penetration, weld profile, HAZ and discontinuities can be evaluated.

Can you perform tube-to-tubesheet mock-up testing?

Yes. Applicable tube-to-tubesheet mock-up welds can be evaluated using the required examination methods and acceptance criteria.

What magnification is used for macro-examination?

For the applicable mock-up requirement described on this page, exposed weld cross-sections may be examined at approximately 10X to 20X magnification.

Can mock-up testing be combined with other weld tests?

Yes. Depending on the qualification program, mock-up evaluation can be combined with mechanical testing, hardness testing, metallography and other applicable examinations.