PROSEDUR

ANALISA KERUSAKAN
(Failure Analyses)
Prof. Dr. Ir. Winarto, M.Sc.

Departemen Metalurgi & Material

Fakultas Teknik Universitas Indonesia

ANALISA KERUSAKAN (FA)

TEKNIK ANALISA KEGAGALAN

(lanjutan)
1. TUJUAN :
Analisa kerusakan harus bisa menentukan/mengetahui
sebab-sebab utama (primary caused) dari suatu kegagalan
sehingga dapat diambil tindakan korektif untuk mencegah
kegagalan yang sama.

Investigasi terhadap kerusakan melibatkan pakar (expertist)

dari berbagai bidang engineering, ilmu-ilmu phisik juga
metalurgi

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2. Langkah-langkah Analisa
Langkah-langkah analisa failure tergantung dari sifat (nature)
dari failure itu sendiri, dan Langkah-langkah utama meliputi:
1) Mengumpulkan historical data dan memilih sampel.
2) Pengamatan visual dan mecatatnya.
3) Pengujian tak merusak (non destructive testing)
4) Pengujian mekanis (destructive testing)
5) Seleksi, identifikasi, melindungi dan membersihkan
spesimen.
6) Pengamatan makroskop dan analisa (fracture surface,
secondary crack dan fenomena permukaan lainnya.

ANALISA KERUSAKAN (FA)

7) Seleksi dan preparasi sampel metalografi

8) Pengamatan mikroskopik
9) Determinasi (menetapkan) mekanisme
perpatahan
10) Analisa Kimia
11) Analisa mekanika perpatahan (fracture
mechanic)
12) Pengujian khusus untuk men-simulasi
kondisi kerja
13) Analisa terhadap seluruh data (bukti), solusi
dan pembuatan laporan (report) serta
rekomendasi

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Analisa Kimia
◼ Pengujian komposisi kimia meliputi:
❖ Analisa komposisi bahan dasar (base metal)
❖ Analisa unsur (inclusion, phase) secara mikro
❖ Analisa hasil korosi (endapan / kerak)

◼ Analisa komposisi bahan dasar (base metal) untuk

menjamin bahwa material yang gagal sesuai dengan
yang telah di-spesifikasi-kan (dengan alat Spectrometer),
sedang untuk mengamati komposisi senyawa secara
mikro dipakai alat Energy Dispersive Spectrometry -
EDS).
◼ Analisa hasil korosi (endapan / kerak) untuk mengetahui
komposisi senyawa hasil reaksi dengan lingkungan.
(dengan alat X-Ray Diffraction - XRD)

ANALISA KERUSAKAN (FA)

Spectrophotometer:
Chemical Composition Test

For chemical
composition of
metal and alloy
e.g.:
Cu, Al, Fe, Mg, Ti,
Zn, Pb, Ni

WAS-AG Foundry Master

SAMPLES %C % Si % Mn %P %S % Al

0.05
ASTM A252 Gr B - - - - -
max

ERW PIPE 0.15 0.28 0.71 0.011 0.001 0.043

SPIRAL PIPE 0.14 0.02 0.89 0.006 0.003 0.033

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XRF vs XRD

ANALISA KERUSAKAN (FA) UJI KOMPOSISI KIMIA (XRD&EDS)

X-Ray Diffraction (XRD) SEM equipped with EDS

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 Struktur mikro Hasil Sambungan Las
ANALISA KERUSAKAN (FA)

Daerah interface / TMAZ Al dan HAZ Al hasil

pengamatan SEM
Pin tools taper
cylindrical

Pin tools threaded

cylindrical

ANALISA KERUSAKAN (FA)

Metalografi Optik
◼ Pemeriksaan Metalografi memberikan informasi tentang
tingkat mutu material (ada cacat atau tidak) yang diguna-
kan serta struktur logam daerah patahan, apakah struktur
tsb sesuai dengan yang dikehendaki (specification).

◼ Adapun cacat (defects) material secara metalurgi al:

❖ Kotoran (inclusion)
❖ Segregasi mikrostruktur
❖ Dekarburisasi
❖ HT yang salah
❖ Un-tempered martensite
❖ Korosi batas butir

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Laboratorium Metalografi & HT

Mikrostruktur duplex stainless steel

Optical Microscopes
Mikrostruktur Daerah Retakan Pipa

ANALISA KERUSAKAN (FA)

METALLOGRAPHY (MACRO)

Macro structure of weld cross Macro structure of weld cross

section on spiral pipe (nital 2%) section on ERW pipe (nital 2%) Mag
Mag 6,5X 6,5X

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Case Hardening
• Case hardening is a
technique where both
surface hardness and
fatigue life are improved for
steel alloys.
• Both core region and
carburized outer case
region are seen in image.
Knoop microhardness
shows case has higher
hardness (smaller indent).
• A carbon or nitrogen rich
outer surface layer (case)
is introduced by atomic
diffusion from the gaseous
phase. The case is typically
1mm deep and is harder
than the inner core
material.

ANALISA KERUSAKAN (FA)

Analisa Mekanika Perpatahan

Fracture mechanics – Griffith Theory of brittle fracture
1 Phenomenon in complete brittle fracture: Deformation under loading -
elastic strain energy – crack propagation – new free surface – increase of
surface energy. The critical stress for crack propagation
σc = (2 E s / πa)1/2
where: E = modulus of elasticity; s = specific surface energy; a = one half
the length of an internal crack

2. Phenomenon in fracture involving some plastic deformation:

Deformation under loading - elastic strain energy – crack propagation –
new free surface – increase of surface energy + plastic deformation
energy
σc = [2 E ( s +  p ) / πa)1/2

◼ where: p = a plastic deformation energy associated with crack extension

where: Gc = critical strain energy release rate; when ( π σ2 a) / E exceeds the value
of Gc, fracture occurs.

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Crack Propagation
Cracks propagate due to sharpness of crack tip
 A plastic material deforms at the tip, “blunting” the
crack.
deformed
region
brittle
plastic

Energy balance on the crack

 Elastic strain energy-
 energy stored in material as it is elastically deformed
 this energy is released when the crack propagates
 creation of new surfaces requires energy

ANALISA KERUSAKAN (FA)

Fracture Mechanics
Studies the relationships between:
❑ material properties
❑ stress level
❑ crack producing flaws
❑ crack propagation mechanisms

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STRESS CONCENTRATION AT CRACKS

◼ For an elliptical crack, can

approximate stress in the
neighborhood of crack

◼ In ductile materials, yielding

(or plastic deformation) will
occur when sm > sy

◼ In brittle materials, when sm

1/ 2
a > sc (critical stress), crack
s m = 2s 0   propagation will occur
 t 
Young’s modulus Surface energy

Not so bad Bad! 1/ 2

 2 E s 
sc =  
Avoid sharp corners  a 

ANALISA KERUSAKAN (FA)

Compact tension (CT) specimen

single edge notch

bend (SENB or
three-point bend)

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FRACTURE TOUGHNESS
◼ Fracture toughness: Kc = Ysc(a)0.5 = Y(2Es)0.5
◼ Kc is a material property
◼ Y ~ 1, depends on geometry

s
units of K :
MPa m
a
or ksi in
Adapted from Fig. 8.8,
Callister 6e.

K = s a K = 1.1s a

ANALISA KERUSAKAN (FA)

FRACTURE TOUGHNESS
increasing

Based on data in Table B5,

Callister 6e.
Composite reinforcement geometry
is: f = fibers; sf = short fibers; w =
whiskers; p = particles. Addition
data as noted (vol. fraction of
reinforcement):
1. (55vol%) ASM Handbook, Vol. 21, ASM
Int., Materials Park, OH (2001) p. 606.
2. (55 vol%) Courtesy J. Cornie, MMC, Inc.,
Waltham, MA.
3. (30 vol%) P.F. Becher et al., Fracture
Mechanics of Ceramics, Vol. 7, Plenum
Press (1986). pp. 61-73.
4. Courtesy CoorsTek, Golden, CO.
5. (30 vol%) S.T. Buljan et al., "Development
of Ceramic Matrix Composites for
Application in Technology for Advanced
Engines Program", ORNL/Sub/85-22011/2,
ORNL, 1992.
6. (20vol%) F.D. Gace et al., Ceram. Eng.
Sci. Proc., Vol. 7 (1986) pp. 978-82.

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Fracture Toughness

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ANALISA KERUSAKAN (FA)

DESIGN AGAINST CRACK GROWTH

• Crack growth condition: K ≥ Kc
Ys a
• Largest, most stressed cracks grow first!
--Result 1: Max flaw size --Result 2: Design stress
dictates design stress. dictates max. flaw size.
Kc 1  Kc 2
sdesign  a max   

Y a max   Ysdesign 

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Design Example: Aircraft Wing

• Material has Kc = 26 MPa-m0.5
• Two designs to consider...
Design A Design B
-- largest flaw is 9 mm -- use same material
-- failure stress = 112 MPa -- largest flaw is 4 mm
Kc -- failure stress = ?
• Use... sc =
Y amax
• Key point: Y and Kc are the same in both designs. Y is a dimensionless parameter; see Callister page 298.

-- Result:
112 MPa 9 mm 4 mm

(sc ) (
amax A = sc amax B )
Answer: (sc )B = 168 MPa
• Reducing flaw size pays off.

ANALISA KERUSAKAN (FA)

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Pengujian Khusus Mensimulasi Kondisi Kerja

◼ Pengujian khusus terkadang diperlukan untuk mensimulasi

keadaan dimana diperkirakan terjadinya kegagalan.

◼ Pengujian simulasi, kondisi lingkungan sangat mungkin sulit

untuk dimengerti dan dipahami. Contoh: kegagalan karena
korosi sangat sulit untuk diulang pada pengujian laboratorium
◼ Disisi lain, pengujian simulasi sering pula dapat membantu
untuk langkah-langkah perencanaan perbaikan yang dapat
menghindari kegagalan yang sama atau dapat memper-
panjang umur penggunaan komponen. Contohnya: Simulasi
evaluasi efisiensi suatu “additive” khusus pada pelumas
dalam mengatasi keausan dan juga “Wind Tunnel” dalam
mensimulasikan kondisi penerbangan, dll.

ANALISA KERUSAKAN (FA)

Penggunaan CFD (Fuent)

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Penggunaan CFD (Fuent)

Gambar. Posisi Kebocoran Suatu Elbow

Gambar. Distribusi Intensitas Tubulensi - R1

Gambar. Alur Jejak Penipisan Pipa Elbow

Gambar. Distribusi Intensitas Tubulensi – R2

◼ Casting Design Simulation

(Reduction of Casting Reject)
❖ Perform an analysis with simulation software (Z-CAST), that can
predict and avoid defect by improvement on design or process

3D Model

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CORROSION & ENVIRONMENTAL BEHAVIOR

TESTING: ASTM & NACE CORROSION TESTS
•General Exposure Testing
•Localized Corrosion (Pitting, Crevice, Intergranular)
•Stress Corrosion Cracking (SCC) Testing and Evaluation
•Immersion Corrosion Testing
•Salt Spray Testing
•Humidity Chamber Testing
•Corrosion Rate Determination:
Low & High Temperature Applications
•Corrosion Immersion Testing (low and high pressure)
•Full Electrochemical (AC & DC) Corrosion Testing

ANALISA KERUSAKAN (FA)

Laboratory of Corrosion & Metal Protection

❖ Various corrosion cell
❖ Corrosion potential measurements in several environments
❖ Polarization methods
❖ Cathodic protection
❖ Electroplating protection and anodizing.

Salt Spray Machine Corrosion Cell

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STRESS CORROSION CRACKING

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◼ Clue in making conclusion :

➢ The main (primary) caused is revealed only by “a
systematic examination of all facts” related to the
case.
➢ Every item of data must be examined and
evaluated for its source, accuracy & relevance to
the entire investigation.
➢ DATA vs Conclusion → logically analyzed &
evaluated → reasonable & consistent
➢ If there is conflict between data & conclusion
(due to incompatible data, error or true but
abnormality) → need an additional testing → “a
sound conclusion”

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Analisa terhadap seluruh data (bukti),

Kesimpulan serta rekomendasi
◼ Technical Report :
A. Background Information
B. Objective
C. Laboratory Investigation:
1. Visual Observation
2. Mechanical Testing
3. Metallographic Testing
4. Fractography Examination (macro & Micro)
5. Chemical Comp. Exam. (Spectro, EDS, XRD/XRF)
6. Summary of Finding
D. Analysis
E. Conclusion
F. Recommendation

TUGAS 3 (Home Work)

1. Jelaskan tujuan pengujian metalografi pada FA suatu material serta
jelaskan pula tahapan dalam “preparasi & pengujian” metalografi !

2. Jelaskan maksud dari pengujian komposisi kimia & peralatan apa saja
yang digunakan untuk pengujian tersebut.

3. Jika saudara dihadapkan pada suatu kerusakan komponen (tabung

boiler) yang pecah dalam arah longitudinal. Jelaskan jumlah sampel yang
harus diambil untuk pengujian metalografi. Mengapa Saudara ambil
sampel sebanyak itu, Jelaskan !
4. Jelaskan cara terbaik dalam pengambilan kesimpulan dari data-data
pengujian yang diperoleh ? Apakah “check-list of question” dapat
membantu untuk pengambilan kesimpulan tersebut ? Jelaskan “check-
list” tersebut !

5. Data apa saja yang didapatkan dari pengujian menggunakan alat

Optical Emission Spectrometry (OES), SEM, Energy Dispersive
Spectrometry (EDS), XRD dan XRF! serta mohon dijelaskan tujuan tes
tersebut secara lebih singkat.

6. Apa tujuan dari pengujian simulasi dan mohon berikan beberapa

contoh mengenai pengujian simulasi secara singkat.
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