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42specimens were of constant cross sectional area. Figure 3.9 is a drawing of the tensilecoupon dimensions that were used for the testing samples.Eyebar 3 from the Bell Ford Bridge was too disfigured and bent from the collapseto be used without further straightening. It was decided that mechanically straightening aspecimen from this eyebar would be beneficial to evaluate the effects from straighteningwithout heat. A section from the eyebar of the same length as the test coupon (18”) wasremoved and measured to determine the amount of curvature and deflection in the piece.The piece was then bent in the center with a deflection of a half inch compared to theends.A three point method was used to straighten the piece. Figure 3.10 is a drawingof the method used to straighten the bent piece. In this method, two vertically fixedsupports hold the piece in place while a plunger pushes the piece past a neutral position.This force counters the residual stresses holding the piece in its original curved shape.The force then creates new residual stresses that again change the shape of the piece.After deforming the piece originally, it was again slightly deformed in the other direction.The piece was then turned over and the three point method was repeated to straighten thepiece even more. This process was repeated until the piece was completely flat. Oncethe piece was bent into a flat shape it was then machined into the standardized tensilecoupon shape.Eyebar 4 from the Bell Ford Bridge had not been heat straightened and had notexperienced much visible damage from the collapse. Therefore, standard non-treatedtensile specimens where machined from this eyebar. These specimens were used tocompare with the other specimens that experienced more damage and repair procedures.Eyebar 5 was similar to Eyebar 4 because it was not damaged as significantly asthe first three eyebars. From Eyebar 5, welded tensile coupons were machined fortesting. The eyebar was cut into sections from which the specimens would be machined.
43The sections of the eyebars where labeled on either side and then cut directly into half.These halves were then beveled and joined together using the shielded metal arc weldingprocess.The joint used for these groove welded specimens was a double V butt joint witha sixty degree incline and a one sixteenth inch land. Figure 3.11 is a detail of theconnection used for welding the specimen. Weld passes were alternated on either side toensure that heat distortion in the piece was minimized.After the initial root pass was completed, the surface of the weld pass was cleanedwith a chisel hammer and wire brush and then back ground on the opposite side wherethe second weld pass was to be placed. This was to ensure the second weld pass fullypenetrated the wrought iron and the initial pass. Figure 3.12 is a photograph of thewelded connection after the initial root pass had been deposited and ground back to theweld metal. After the second weld pass, the specimen was again cleaned with a chiselhammer and wire brush and the piece was turned over and slightly back ground for thefollowing pass. This process continued until the final weld passes were above the surfaceof the specimen on either side. A more detailed description of the welding procedureutilized for this testing is provided in Appendix D.Once the joint was completely welded, the surface of the piece was then groundflush so the piece was completely flat. From this smooth piece the tensile couponspecimen was then cut out of the center of the piece. Cutting the specimen out of thecenter of the piece helped to ensure that only an adequate weld would be tested. This isbecause the ending and starting points of the weld, which usually include impurities andair pockets, were removed during machining. To evaluate the effect of weld metal onthe wrought iron, two different weld metals, E6010 and E7018 SMAW, were used toweld different specimens together.
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Purdue UniversityPurdue e-PubsJTRP
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1. Report No. 2. Government Accessi
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epairing a bent wrought iron tensio
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vPageCHAPTER 3TEST PROCEDURES FOR M
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ixLIST OF FIGURESFigurePageFigure 1
Page 12 and 13: xiFigurePageFigure 3.30 Top View of
Page 14 and 15: xiiiFigurePageFigure 5.12 Typical T
Page 16 and 17: xvAppendix FigurePageFigure D.7 Ini
Page 18 and 19: viiiAppendix TablePageTable A.5 Det
Page 20 and 21: iiiThe authors would also like to t
Page 22 and 23: 2but also what material properties
Page 24 and 25: 4microstructure of the metal. The c
Page 26 and 27: 62. LITERATURE SEARCHBefore experim
Page 28 and 29: 8imperfections, the performance of
Page 30 and 31: 10wrought iron. Adding the slag aft
Page 32 and 33: 12method for manufacturing wrought
Page 34 and 35: 14patents for their process and tra
Page 36 and 37: 16This method of testing of structu
Page 38 and 39: 18plot of this percent elongation d
Page 40 and 41: 20significant variation in the perc
Page 42 and 43: 22The practice of restoring histori
Page 44 and 45: 24Elleby, Wallace W. Sanders, F. Wa
Page 46 and 47: 26From all the surveys that were di
Page 48 and 49: 28Table 2.1 Average Ultimate Streng
Page 50 and 51: 30Figure 2.3 Wrought Iron “Sponge
Page 52 and 53: 32Histogram of Kirkaldy Wrought Iro
Page 54 and 55: 34Percent Occurance in Range - %45.
Page 56 and 57: 3660Combined Wrought Iron BarsTensi
Page 58 and 59: 38The Bell Ford Bridge consisted of
Page 60 and 61: 40Two. These samples were taken fro
Page 64 and 65: 44Along with rectangular tensile co
Page 66 and 67: 46After the initial test loading wa
Page 68 and 69: 483.6 Fatigue TestingTo develop a b
Page 70 and 71: 50The final specimen category consi
Page 72 and 73: 52This analysis was completed using
Page 74 and 75: 54After the initial test was comple
Page 76 and 77: 56completed, but before the surface
Page 78 and 79: 58readings, load cell readings and
Page 80 and 81: 60Figure 3.3 Donated Eyebars 4 and
Page 82 and 83: 62Figure 3.7 Heated Areas in Blue o
Page 84 and 85: 64Figure 3.11 Detail Used in Groove
Page 86 and 87: 66900080007000y = 27.153xR 2 = 0.99
Page 88 and 89: 68Figure 3.19 Charpy Impact Testing
Page 90 and 91: 70Figure 3.23 Eyebar Connection in
Page 92 and 93: 72Figure 3.27 Eyebar A After Filler
Page 94 and 95: 74Figure 3.31 Side View of Finished
Page 96 and 97: 76Figure 3.35 Front View of Eyebar
Page 98 and 99: 78strength from the existence of pe
Page 100 and 101: 80The carbon content present in the
Page 102 and 103: 82value may not be very accurate bu
Page 104 and 105: 84strengths was found to be 29,940
Page 106 and 107: 86wrought iron bars were investigat
Page 108 and 109: 88stresses are induced. These perma
Page 110 and 111: 90toughness the material. The test
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92From the finite element analysis,
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94Table 4.1 Chemical Analysis of Ey
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96Table 4.3 Tensile Coupon Test Res
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98Table 4.5 Charpy Impact Test Resu
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100Table 4.7 Comparison of Strain G
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102Figure 4.1 Typical Micrograph of
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104Figure 4.5 Fracture Surface of D
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106Comparison of Tensile Strengthfo
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108Combined Wrought Iron Bar Histor
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110Figure 4.17 Macrograph of Weld u
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112Figure 4.21 Cleavage Fracture of
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Figure 4.25 Elongation of Hole in E
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116signs on or near the bridge that
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118testing of historic wrought iron
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120so that they would act in symmet
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122The reasons for the differences
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124The second corrosion pattern mod
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126Keating (1984) stated that the s
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128charcoal fire until it is red ho
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130Figure 5.3 Picture of Bottom Cho
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132Figure 5.7 Using Force After Usi
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134Figure 5.11 Reassembling a Pin C
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1366. SUMMARY, CONCLUSIONS AND IMPL
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138rectangular in shape. These eyeb
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140were joined together with a full
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1424. The Charpy impact energy of t
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144connections are unsymmetrical, i
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146LIST OF REFERENCESAASHTO (1998).
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148Hodgkinson, Eaton (1840). Experi
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150Appendix A. Data Collected From
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152Table A.1 Wrought Iron Bar Tensi
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154Table A.1 (continued) Wrought Ir
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156Table A.2 (continued) Wrought Ir
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158Table A.3 Wrought Iron Angle Ten
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160Table A.4 (continued) Summary of
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162Table A.4 (continued) Summary of
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164Table A.5 (continued) Detailed I
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184Table A.7 Tensile Strength Data
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186Table B.1 Example Historic Wroug
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188DepartmentofTransportationIf you
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190CountyIf your organizationdoes m
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192County 16: County bridge inspect
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194State 13: Included in original d
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196Figure C.1 Diagrams Showing Loca
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198Figure C.3 Heating of Eyebar fro
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200Figure C.7 Double V Butt Joint u
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202Figure C. 11 Welded Tensile Coup
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204Figure C.15 Tensile Coupon from
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206Figure C.19 Cooling Bath with Su
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208Figure C.23 Side View of Eyebar
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210Figure C.27 Eyebar End Connectio
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212Appendix D. Welding Procedure fo
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214D.2 Filler Weld for Eyebar Conne
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216Figure D.1 Weld Joint Detail Use
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Figure D.5 Completed Weld Before Su
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220Figure D.7 Initial Pass Pattern
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