failure analysis presentation1 rev1.ppt

8/18/2019 FAILURE ANALYSIS Presentation1 REV1.ppt

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PRESENTED FORHESS (INDONESIA – PANGKAH)

LIMITEDDate : 1 October 201

No! Doc"#e$t: 002%TMP%HESS%201

PT S&R'EOR INDONESIA

By: DR.-ING.IR. PUTU M. SANTIKA


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ONTENT

INTRODUCTIONDEFINITION

CAUSE OF FAILURE

PROCEDURE FOR FAILURE ANALYSIS

OBJECTIVE

REFERANCE

METHODOLOGY

FINAL REPORT


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INTRODUCTION AND

THEORITICAL BACKGROUNDFailure analyi i a !e"#ni$ue %#ere &a"!

are 'a!#ere( !#r)u'# in*e!i'a!i)n an(!e!in' an( analy+e( !) (e!er,ine !#e r))!"aue )& a -r)(u"! &ailure. Ty-i"ally &ailure "an /e a!!ri/u!e( !) any

)ne )r a "),/ina!i)n )& !#e &)ll)%in',e"#ani, an( ,ay in*)l*e i,-r)-er,a!erial ele"!i)n0 (ei'n0 &a/ri"a!i)n0-r)"ein' an(1)r )-era!i)n al)n' %i!#e2-)ure !) e2!re,e en*ir)n,en! !#a!!#ey are n)! (ei'ne( &)r.


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DEFINITION

Fa*+"re: A !er, %#i"# in&er !#a! a "),-)nen! )rae,/ly in a !a!e )& (a,a'e !#a! ren(er i! n)l)n'er "a-a/le )& relia/ly -er&)r,in' i! in!en(e(&un"!i)n.Seco$,ar- Da#a.e: Ina(*er!en! "#an'e !)

a"),-)nen! !#a! ,ay )r ,ay n)! a3e"! &un"!i)nali!y.Pr*or Da#a.e: (a,a'e !#a! ,ay #a*e ")n!ri/u!e(

!) !#e &ailureo$/e"e$t*a+ Da#a.e: (a,a'e !#a! reul!e( (ue

!) ")n!inue( )-era!i)n -)! &ailure

Meca$*ca+%E$*ro$#e$ta+ Da#a.e: u/4e"!e( !)!#e &aile( "),-)nen!Han(lin'Cleanin'S!)ra'e


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MATERIAL

OPERATIONAL

D E S I G

N

M A N U F A C T U R E

FAILURE


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PROCEDURE FOR FAILUREANALYSIS5. Cale"!i)n )& /a"6'r)un( (a!a an( ele"!i)n )& a,-le7. Preli,inery a2a,ina!i)n )& !#e &ailure -ar! 8*iual

e2a,ina!i)n an( re")r( 6ee-in'9

:. N)n (e!ru"!i*e !e!in'

;. Me"#ani"al !e!in' 8in"lu(in' #ar(ne an( !)u'#ne!e!in'9

. Ma"r)")-i" e2a,ina!i)n an( analyi an( -#)!)'ra-#i"()"u,en!a!i)n

?. Mi"r)")-i" e2a,ina!i)n an( analyi 8e, ,ay/ene"eary9

@. Sele"!i)n an( -re-ara!i)n )& ,e!all)'ra-#i" e"!i)n

. E2a,ina!i)n an( analyi )& ,e!all)'ra-#i" -e"i,en5. De!er,ina!i)n )& &ailure ,e"#ani,55. C#e,i"al analyi

57. Analyi )& &ra"!ure ,e"#ani"

5:. Te!in' un(er i,ula!e( er*i"e ")n(i!i)n 8-e"ial !e!9

5;. Analyi )& all !#e e*i(an"e0 &)r,ula!in' ")n"lui)n an(%ri!in' re-)r!


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UESTIONS TO ASK SURFACE OF FRACTURE

SURFACE OF PART

GEOMETRY AND DESIGN

MANUFACTURING AND PROCESSINGPROPERTIES OF THE MATERIAL

RESIDUAL AND APPLIED STRESS RELATIONSHIP

ADJACENT PART

ASSEMBLY

SERVICE CONDITIONS

ENVIRONMENTAL REACTION


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FAILURE ANALYSIS

I an e2!re,ely "),-le2 u/4e"! an( in*)l*earea )& ,e"#ani"0 -#yi"0 ,e!allur'y0"#e,i!ry an( ele"!r)"#e,i!ry0,anu&a"!urin' -r)"e0 !re analyi0 (ei'nanalyi0 an( &ra"!ure ,e"#ani".

Be"aue i! i nearly i,-)i/le &)r any )ne

-er)n !) /e an e2-er! in all !#ee =el(0 i! ie2!re,ely i,-)r!an! !) 6n)% %#en !) ee6#el-.


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OBJECTIVE

T#e /ai" )/4e"!i*e i !) =n( )u! !#e

-reli,inary "aue )& &ailure1r))!"aue an( a&!er !a6in' a ")rre"!i*ea"!i)n ui!a/le ,eaure are !) /e

!a6en in )r(er !) a*)i( re"urren"e in&u!ure.


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REFERANCE

ASM Han(/))6 V)lu,e 5:0

API RP


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METHODOLOGY

DESCRIPTION5. Hi!)ry Da!a C)lle"!i)nHi!)ry (a!a ")lle"!i)n #)ul( ")lle"! !)

6n)% -e"i="a!i)n )& ,a!erial0 (ei'n0)-era!in' #i!)ry an( -re*i)u in-e"!i)n.

T#i ,e!#)( )/4e"!i*e i !) 6n)% %#a! any&ailure )r ,i!a6e )n -re*i)u -r)"e.


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Hi!)ry Da!a )& Pi-e 8EAMPLE9 T#e H)le P)i!i)n a! > )"l)"60

T#e -r)(u"e %a!er "a,e &r), !#e (i!illa!i)n )&#y(r)"ar/)n li$ui( an( %a!er &)r,a!i)n0

T#e Li$ui( #a /een !e!e( )n la/. T#e reul! i H7S .;--, an( )il ")n!en! : 5 --,0

T#e -i-e i a! (ea( en( -)i!i)n 8I),e!ri" (ra%in'

a!!a"#e(90 T#e -reure )& li$ui( %#en i! ue( i .< /ar0 T#e -i-e #a /een ue( in"e Fe/ruary 7 T#e li&e !i,e i (ei'ne( &)r 7< year0 T#e Pre*i)u in*e!i'a!i)n #a n)! ()ne ye!0

T#e Pi-e i n)! &ully -r)!e"!e( &r), ")rr)i)n0 e.' ")a!in'0in#i/i!)r0 "a!#)(i" )r an)(i"0

T#e Ma!erial -e"i="a!i)n &)r -i-e 7 ; Car/)n !eelASTM A5> Gra(e B 8ASME B:>.59 SCH 5> Sea,leBE.


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7. Viual in-e"!i)nDurin' re"ei-! in-e"!i)n0 !#e analy! #)ul( *eri&y !#e

nu,/er )& -ar!0 n)!e an( -#)!) ()"u,en! !#e

")n(i!i)n )& !#e -ar!. Are"ei*e( -#)!)()"u,en!a!i)n i *ery ue&ul e-e"ially )n"e !#e -ar!are e"!i)ne( &)r !e!in'. D)"u,en!a!i)n #)ul( /e")n(u"!e( !#r)u'#)u! !#e analyi ) !#a! !#ein&)r,a!i)n "an la!er /e #are( %i!# an( (e"ri/e( !)

all ")n"erne( -ar!ie. C)l)r -#)!)'ra-#y ire"),,en(e( !) illu!ra!e !#e ")n!a,inan! an( #)%(i")l)ra!i)n )r !e,-er ,ar6. Ma"r) e2a,ina!i)nuin' !ere),i"r)")-y 8


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:. NDTN)n(e!ru"!i*e !e!in' !e"#ni$ue u"# a Ul!ra)ni"

T#i"6ne0 Meaure,en! P#ae( Array Ul!ra)ni" Te!8PAUT90 ,a'ne!i" -ar!i"le 8MT90 L)n' Ran'e Ul!ra)ni" Te!8LRUT9 are *ery in!ru,en!al in (e!e"!in' ur&a"e an(in!ernal an),alie in a "),-)nen!. Pi!!in' ")rr)i)n a

General ")rr)i)n0 Cra"60 #)! !ear0 ")l( #u!0 #rin6a'e-)r)i!y0 *)i(0 la"6 )& &ui)n0 (ela,ina!i)n0 in"lui)n an(nu,er)u )!#er (e&e"! "an /e (e!e"!e( uin' !#ee!e"#ni$ue %i!#)u! i,-airin' !#e -ar! ue&ulne. Ty-e )&,a!erial an( !#e 'e),e!ry %ill (i"!a!e !#e /e! ,e!#)( !)ue.

LRUT -e"iall in-e"!i)n &)r ")lle"!in' (a!a #)% -i-e")n(i!i)n0 $uali!y )& -i-e an( 'eneral ")rr)i)n !) #el-"al"ula!in' re,ainin' li&e an( (a!a )& !#e -i-e.

In&rare( "an /e ue( in !#i ,e!#)(. I& ,a!erial )n #ea!-r)'re0 "ra"6 ,ay ,a(e &r), #ea! un-e"i=e(.


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;. CHEMICAL COMPOSITION EAMINATION

All)y i(en!i="a!i)n #)ul( /e -er&)r,e( ) !#a! !#ereul! "an /e "),-are( !) -e"i=e( re$uire,en! )rin(u!ry !an(ar(. S),e &ailure )""ur /e"aue )&,a!erial ,i2u- a! !#e ,ill0 %are#)ue )r !#e&a/ri"a!i)n !a'e. In a((i!i)n !) !#e /ul6 ,a!erialanalyi uin' )-!i"al e,ii)n -e"!r)")-y 8OES9 )r

in(u"!i*ely ")u-le( -la,a 8ICP9 !e"#ni$ue0 analy+e")rr)i)n -r)(u"!0 in"lui)n0 ur&a"e (e-)i! an(-la!in'1")a!in' i& -reen! uin' ener'y (i-eri*e 2ray analyi 8EDS9 (urin' "annin' ele"!r)n ,i"r)")-ye2a,ina!i)n. A((i!i)nally0 2ray (i3ra"!i)n 8RD9analyi )& ")rr)i)n (e-)i! ,ay /e u!ili+e( &)r -#ae

i(en!i="a!i)n )& "ry!alline ,a!erial an( "an -r)*i(ein&)r,a!i)n )n uni! "ell (i,eni)n. T#e analy+e(,a!erial i =nely 'r)un(0 #),)'eni+e(0 an( a*era'e/ul6 "),-)i!i)n i (e!er,ine(. T#i !e"#ni$ue %ill"),-li,en! !#e EDS reul! /y i(en!i&yin' i& !#ein(i*i(ual ele,en! u"# a )(iu, an( "#l)rine

(e!e"!e( are a"!ually -reen! in !#e &)r, )& )(iu,"#l)ri(e.


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Har(ne Te! T#e )!#er ,)! "),,)n !e!0 e-e"ially i& !#e

"),-)nen! i !)) ,all an( n)! ui!a/le &)r !enile!e!in'0 i !#e #ar(ne !e!. T#ee reul! ,ay al)/e ue( !) e!i,a!e a--r)2i,a!e !enile !ren'!#.

Ty-i"al ,e!#)( in"lu(e Brinell0 R)"6%ell 8e.'. HRC0HRB0 HRF90 u-er="ial R)"6%ell 8e.'. HR:T0HR5(ia,e!er /all an( 5 6' l)a(9. Brinell ,ay /e ue(

&)r /)!# #ar( an( )&! ,a!erial %i!# ei!#er a:06' )r a


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C#ar-y i,-a"! !e!in'I )ne !#e ,)! "),,)n %ay )& (e!er,inin' !#e

!)u'#ne )& a ,a!erial. I! i al) )ne )& !#e ,)!re*ealin' !e! &)r (e!e"!in' !#e l)% !e,-era!ure/ri!!lene in )!#er%ie (u"!ile ,a!erial. C#ar-y !e!ue a ,all -e"i,en0 !y-i"ally %i!# a *n)!"# in i!.

T#e -e"i,en i u--)r!e( #)ri+)n!ally a! i! en( in!#e i,-a"! ,a"#ine an( !ru"6 )n !#e i(e )--)i!e!) !#e n)!"# /y a %in'in' -en(ulu, !y-e #a,,er.

T#e ener'y (ii-a!e( /y &ra"!urin' !#e -e"i,en i,eaure( in &!l/ an( "an /e -l)!!e( a'ain! !#e !e!!e,-era!ure. A #)%n in !#e 'ra-# /el)% "ar/)n an(all)y !eel /e#a*e in a uni$ue ,anner "),-are( !)

)!#er ,a!erial 8e.'. alu,inu, )r !ainle !eel9an( "an &ail in a /ri!!le ,anner %#en u/4e"!e( !) l)%!e,-era!ure. T#i (u"!ile !) /ri!!le !rani!i)n )""ura/ru-!ly %#en "er!ain !e,-era!ure are rea"#e(.


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Ener'y A/)r/e(


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>.Mi"r)")-i" E2a,ina!i)nMe!all)'ra-#i" e2a,ina!i)n are ")n(u"!e( !)

(e!er,ine !#e a"!ual -r)"ein'1#ea! !rea! ")n(i!i)n)r i& !#e "#e(ule( -r)"ein' !e- %ereina(*er!en!ly ),i!!e( )r in")rre"!ly -er&)r,e(.Sa,-le -re-ara!i)n &)r !#i !y-e )& analyi i

"ri!i"al. T#e &ailure area #)ul( /e -reer*e( an( any"u!!in' )r e"!i)nin' #)ul( /e ()ne %ell a%ay &r),!#e &ra"!ure ini!ia!i)n area.

E!"#in' %i!# a ui!a/le "#e,i"al re*eal 'rain/)un(arie an( -#ae an( all)% y)u !) *ie% !#e

,i"r)!ru"!ure. T#e -ar! -r)"ein' #i!)ry 8"a!0&)r'e( )r %r)u'#! ,a!erial90 #ea! !rea! ")n(i!i)n0-reen"e )& in"lui)n0 e")n(ary -#ae0 "#e,i"al*aria!i)n 8e're'a!i)n90 'rain (e&)r,a!i)n0 %el( 4)in! "an all /e re*eale(.


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M*cro.ra3 /o4*$. te .ra3*te$o,"+e/ *$ a ,"ct*+e ca/t *ro$ 3art(etce, co$,*t*o$)


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?.Fra"!)'ra-#yHi'# ,a'ni="a!i)n e2a,ina!i)n )& !#e &ra"!ure ur&a"euin' !#e ele"!r)n ,i"r)")-e 8SEM9 i *ery in!ru,en!al

in &ailure in*e!i'a!i)n. Analyi )& !#e &ra"!ure &ea!urean( rela!in' !#e !)-)'ra-#y !) !#e "aue )r /ai",e"#ani, )& &ailure all)% !#e analy! !) (e!er,ine!#e &ailure ,)(e )& !#e "),-)nen!. SEM )3er 'rea!er

(e-!# )& &)"u !#an )-!i"al ,i"r)")-e an( all)% r)u'#&ra"!ure ur&a"e e2a,ina!i)n -)i/le a! *ery #i'#,a'ni="a!i)n.

Vari)u ,)(e )& &ailure !#a! are "),,)nly e2-erien"e(are 'i*en /el)%

Ductile rupture Ty-i"ally !#e ,ain (i3eren"e /e!%een

(u"!ile an( /ri!!le &ra"!ure i !#e a,)un! )& -la!i"(e&)r,a!i)n !#a! !#e ,a!erial e2-erien"e /e&)re !#e&ra"!ure. Du"!ile ,a!erial e2#i/i! i'ni="an! a,)un! )&(e&)r,a!i)n %#ile /ri!!le ,a!erial #)% *ery li!!le )r n)a--re"ia/le (e&)r,a!i)n /e&)re &ra"!ure. Du"!ile &ailureini!ia!e %i!# ,i"r)*)i(. #en (e&)r,a!i)n ")n!inue an(!#ee ,i"r)*)i( enlar'e !) &)r, a "ra"60 !#e e-ara!i)ni ai( !) #a*e )""urre( (ue !) ,i"r)*)i( ")ale"en"e.


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SEM ,i"r)'ra-# #)%in' !y-i"al (u"!ile

&ra"!ure &ea!ure.


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Brittle fracturesCan )""ur in !%) (i!in"! ,)(e0 !ran'ranular

"lea*a'e an( in!er'ranular e-ara!i)n. Clea*a'e&ra"!ure -r)'ree al)n' "ry!all)'ra-#i" -lane )& a,a!erial an( lea*e le('e )r !e- /e#in(. S),eal) in"lu(e ri*er -a!!ern. In!er'ranular &ra"!ure0al) 6n)%n a r)"6 "an(y in ,a!erial %i!# ")are'rain i+e 8i.e. "a!in'9 i an)!#er &)r, )& l)% ener'y&ailure !#a! uually in(i"a!e a er*i"e en*ir)n,en!

)r -r)"ein' -r)/le,. Ty-i"al "aue are $uen"#"ra"6in'0 !e,-er e,/ri!!le,en!0 #y(r)'ene,/ri!!le,en!0 li$ui( ,e!al e,/ri!!le,en!0-re"i-i!a!i)n )r !ran&)r,a!i)n )& (e!ri,en!al -#ae(ue !) #i'# !e,-era!ure e2-)ure )r !re")rr)i)n "ra"6in'.


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SEM #*cro.ra3 /o4*$. t-3*ca+

br*tt+e5c+eaa.e 6ract"re 6eat"re/!


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Fatigue fractures )""ur a! !re le*el /el)% !#eyiel( !re )& !#e ,a!erial. T#ey are -r)(u"e( /y

!ree re-ea!e( !#)uan( )r ,illi)n !i,e8"aue( /y "y"li" l)a(in'9. T#ey are &)un( in #a&!0'ear !ee!#0 &a!ener0 *e#i"le &ra,e0 an( *ari)u,a"#ine "),-)nen!. T#e "ra"6 -r)-a'a!e in a-r)'rei*e ,anner (ue !) Qu"!ua!in' !ree.Cra"6 ini!ia!e a! ei!#er ,e!allur'i"al 8e.'. -)r)i!y0

in"lui)n0 #ar( )r )&! -)!9 )r 'e),e!ri"al 8#ar-"#an'e in "r) e"!i)n0 !)e )& a %el(0 ")rr)i)n-i!0 e!".9 !re ")n"en!ra!i)n -)in!. T#e &a!i'ue-r)"e ")ni! )& !#e &)ll)%in' !a'e "ra"6ini!ia!i)n0 "ra"6 -r)-a'a!i)n an( =nal u((en

&ra"!ure )& !#e re,ainin' "r) e"!i)n. T#e,a2i,u, "y"li" !re !#a! "an /e a--lie(in(e=ni!ely un(er &a!i'ue ")n(i!i)n i "alle( !#een(uran"e li,i! )& !#e ,a!erial a illu!ra!e( in !#eSN "ur*e /el)%. F)r !eel0 !#e en(uran"e li,i! ia--r)2i,a!ely ; )& !#e !enile !ren'!#.


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SEM #*cro.ra3 /o4*$.*$ter.ra$"+ar 6ract"re 6eat"re/


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@.STRESSSTRAIN ANALYSIS

S!ru"!ural analyi uin' !#e Fini!e Ele,en!Me!#)( ,)(elin' %i!# re&eren"e !) !#e i,-)i!i)n)& !#e re$uire( 1 a"!ual. Reul! )& (i,eni)nalin-e"!i)n0 re*ie% )& (ei'n (ra%in' an( !#ereul! )& 'a!#erin' in&)r,a!i)n a/)u! !#e ,a!erial0!#e /ur(en )& !#e l)a( 8,a 1 ")n(u"!)r

(i,eni)n an( %in( -ee(90 !#e ")n(i!i)n )& !#e&)un(a!i)n an( !#e =nal "),-le!ene )& !#e/ra"in' !#a! #a /een ()ne /e&)re ,a!erial iue( a in-u! (a!a &)r i,ula!i)n /y =ni!e ele,en!,e!#)(. Ma!erial )/4e"! are ,)(ele( %i!#)&!%are Fini!e Ele,en! Me!#)( 8FEM9 )r "an /e,)(ele( %i!# )!#er i,ula!i)n )&!%are. Fr), !#ereul! )& !#ee i,ula!i)n %ill )/!ain in&)r,a!i)na/)u! !#e l)"a!i)n )& !#e ,e,/er 1 ele,en! un(er!eni)n 1 /i''e! l)a( %#ere i! %ill /e ue( !)(e!er,ine !#e "aue )& &ailure.


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E7a#3+e o6 Stre// D*rt*b"t*o$

Y

R

:.>7>

:.;B>

:.5@>

7.A>>

7.?;>

7.

7.:B>

7.B@>

5.@>>

5.>;>

5.;7>

5.7B<

B.A@<

B.?><

B.


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FINAL REPORT

Re-)r! %ill /e ")n!en! a &)ll)%Failure Su,,ary

In*e!i'a!i)n Pr)"e(ure

Rele*an! In&)r,a!i)n

Si!e a,-lin'1(a!a ")lle"!i)n ,e!#)(In"i(en!1Failure C#r)n)l)'y

Failure Analyi

Bai" )& In!erna!i)nal S!an(ar( rela!e( %i!# !#eae,en!

De(i"a!e( Per)nnel !) -er&)r, !#e ae,en! 8-r)4e"!)r'ani+a!i)n "#ar!9

Li! )& ,a!erial an( e$ui-,en! &)r ae,en! in"lu(in'"er!i="a!e 8)nly &)r ,a4)r e$ui-,en!1,a!erial9


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Analyi

Failure Caue an( C)n!ri/u!in' Fa"!)r

E,er'en"y Mana'e,en! 8i& any9

Fin(in' a !) Caue an( C)n!ri/u!in' Fa"!)r

Dire"!i*e an( De!ail Re"),,en(a!i)n

P#)!)'ra-#

Si,ilar Failure in An)!#er In(u!rie a a"),-ari)n 8I& any9

failure analysis presentation1 rev1.ppt

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