TECH TIP: Destructive Testing 101


Destructive Testing 101


The Importance of Destructive Testing 
Performing Tests in the Shop. 

With the advanced materials being used during vehicle production such as HSS and UHSS, destructive testing is a must in the collision repair industry to ensure proper and safe repairs.

Whether we are using Resistance Spot Welding or MIG/Mag welding, we must perform a destructive test before welding on the actual application. This helps ensure that the weld settings are correct and the welder is functioning properly. 


How to Perform a Destructive Test:

Click here to watch video 

In the shop, we have two destructive tests: Twist Test and Peel Test. Which test is best to perform depends on the type of weld being done and the material used. 

The Peel Test is best performed on a resistance spot weld (see image below).

  • This test done by clamping the test material in the vice and peeling the top layer from bottom using rounded end channel locks.
  • With this test we should see the weld nugget stay in tact while tearing a hole in one of the layers. 
  • The "Twist test" uses a vice and a hammer. Using the hammer hit up and down on sample "twisting" the weld until it comes apart.
  • NOTE: This test may be harder to complete on HSS and UHSS

The Twist Test this can be done on resistance spot welds or plug welds. 































  • This test is performed by clamping one layer in the vice and twisting top layer from bottom.
  • Using the hammer hit up and down on sample "twisting" the weld until it comes apart. 
  • With this test we should tear a hole from one of the layers for a successful test. 
  • NOTE: According to I-CAR standards: On an 8mm Plug Weld, a 5-10mm hole should tear out from bottom coupon depending on the material and stack up.


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