Nur Subeki

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Kapal yang terbelah, kenapa?

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Analisis kegagalan adalah suatu aktifitas sangat
penting; analisa terhadap kegagalan metalurgis ini
digunakan untuk menentukan penyebab dari
kegagalan-kegagalan agar dimasa depan kejadian-
kejadian ini bisa dicegah. Dari sudut pandang
engineering, penggunaan teknik analisa kegagalan
dapat menghasilkan umpan balik yang berharga
untuk mengatasi masalah disain dan keterbatasan
kemampuan material.
Peningkatan kemampuan material untuk mencegah
terjadinya kegagalan diperlukan untuk
meningkatkan factor safety. Namun seberapa
besarkah faktor safety ini diperlukan. Perencanaan
secara overdesign suatu komponen menyebabkan
pemborosan secara ekonomis dan menyebabkan
overload pada komponen lain dalam suatu struktur.
Underdesign suatu komponen mengarah kepada
kegagalan dini, yang secara ekonomis sia-sia dan
membahayakan kehidupan manusia
Failure Analysis and Life Assessment of
Structural Components and Equipment

LIFE ASSESSMENT of structural components is used to

avoid catastrophic failures and to maintain safe and reliable
functioning of equipment.

A failure is often defined as the rupture, fracture, or

cracking of a structural member. A component, in practice,
is deemed to have failed when it can no longer perform its
intended function safely, eliably, and economically.

A steam turbine blade whose tip has eroded affects

turbine efficiency and hence affects the economics of
operation adversely. The blade should therefore be replaced
even though it can continue to operate.
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Component failures are thus defined in terms of
“functional” rather than “structural” failures.
Replacement of parts can be based on economic
considerations, reliability, and material properties.

In the discipline of life assessment, equipment and

structures are evaluated to determine if they are
suitable, reliable, and economical for continual
service. If deemed unreliable, the equipment or
structure may be repaired, refurbished, or replaced.

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 Penyebab Kegagalan;

Corrosion, SCC,
burst, etc. delayed fracture
Static fracture,
Indirect fatigue 10%
5% 5%
13%
Simple fatigue
11% 58%
8%

Thermal fatigue
Contact rolling fatigue
Corrosion fatigue
Low cycle fatigue

-90% of failures are directly or indirectly caused by fatigue

Classification of failures according to cause in an industrial investigation on

a wide variety of steel components and structures.
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 Proporsi Komponen yang Gagal

Wire Others
Castings Rope
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15 6
Gears
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Welds
77
Pulleys
Rolls Bolts Shafts
28 32 56

about 90% of fatigue cracks are initiated at stress concentrated parts

Classification of failures according to failed members in an industrial

investigation on a wide variety of steel components and structures
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Tinjauan Ekonomi

An economic study estimated the cost of fracture in

United State in 1978 at $119 billion. Furthermore,
the study estimated that the annual cost could be
reduced by $35 billion if current technology were
applied, and that further fracture mechanic
research could reduce this figure by an additional
$28 billion.

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 Usaha untuk mengatasi

John Mann reported at about 100.000 books with references to fatigue.

Compared to less than 100 publications in the 19th century, the work spent
on fatigue investigation in the 20th century is very huge.
When large number of publications not enough to cover all problems
related to fatigue failures, when many conferences on fatigue of
structures and materials for the forthcoming years of the 21st century still
planned, when our technology in the modern century still have many
problems related to fatigue failures, when many of our passenger
aircrafts crashed to the ocean, when fatigue problem apparently not yet
fully solved after more than 100 years, there is something to be explained.
We still have much homework to eliminate fatigue problems from our
industrial products.

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 Beberapa Contoh Tragedi

1. In January 1954, the Comet crashed into the Mediterranean Sea.

At high altitudes, the Comet cabin pressure was 57 kPa higher than
outside pressure. The design stress for 57 kPa was 40 % of the
tensile strength of the aluminum alloy.

2. In 1967 the Point Pleasant Bridge at Point Pleasant, West

Virginia collapsed without warning. A cleavage fracture in an eye-
bar caused by the growth of a flaw to critical size was responsible
for the collapse. The initial flaw was due to fatigue or stress
corrosion cracking. This failure has had a profound influence on
subsequence design requirement established by AASHTO
(American Association of State and Highway and Transportation
Official).

3. In the end of 1960s the catastrophic crashes of F-111 airplane were

attributed to brittle fracture of member containing preexisting
flaws .

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The tragic failures that had a great impact on structural designs and
life assessment developments.

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The tragic failures that had a great impact on structural designs and
life assessment developments.

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The tragic failures that had a great impact on structural designs and
life assessment developments.

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Definisi Fatik menurut ASTM;
Suatu proses perubahan struktur progressive localized yang terjadi
dalam subyek bahan pada suatu kondisi yang menghasilkan
tegangan-tegangan dan regangan-regangan fluktuasi pada beberapa
titik atau titik-titik dan dapat memuncak menjadi crack atau
fracture total setelah jumlah fluktuasi cukup

Empat kata kunci;

1. Progressive adalah proses fatik berlangsung pada periode waktu
pemakaian.
2. Localized bahwa proses fatik berlaku pada luasan lokal yg
mempunyai kondisi tegangan atau regangan tertinggi
3. Crack bahwa proses kegagalan dimulai dengan tumbuhnya suatu
retakan mikro yg tumbuh secara terus menerus.
4. Fracture bahwa tahap akhir dari seluruh proses fatigue adalah
pemisahan komponen menjadi beberapa bagian.

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Tinjauan Histori
In the 18th century, in Europe, train and railways industry grow fast.
Wohler (1819-1914) performed systematic investigation of fatigue
Gerber investigate the effect of mean stress on fatigue
Goodman proposed a simplified theory concerning mean stresses.
Griffith In 1920 found the strength of glass depended on the size of microscopic
cracks. He became the father of fracture mechanics.
B.P. Haigh reported concepts of notch strain analysis and self-stresses.
Horger reported that roller working can suppress crack growth rate.
Miner reported a linear cumulative fatigue damage criterion. The linear fatigue
damage criterion is now recognized as the Palmgren-Miner law.
Irwin introduced the stress intensity factor KI, the basis of LEFM
Manson-Coffin reported relation between plastic strain amplitude and fatigue life.
The basis for current notch strain fatigue analysis.
Paris reported crack growth rate could best be described using ∆K.
Rice proposed the J-integral to provide a loading parameter for the characterization
of monotonic, nonlinear fracture in rate-dependent.
Dowling proposed a power law characterization of fatigue crack under elastic
plastic condition based on the cyclic J-integral.

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Several procedures to predict problems associated
with fatigue crack growth

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 Tahapan analisa kegagalan. (Wulpi, 1999):
1. Pengumpulan data dan pemilihan sampel.
2. Pemeriksaan pendahuluan pada komponen yang
gagal melalui pemeriksaan visual dan pencatatan.
3. Pengujian tidak merusak.
4. Pengujian mekanik seperti uji kekerasan dan uji
ketangguhan.
5. Pemilihan, identifikasi, pemeliharaan dan atau
pembersihan benda uji.
6. Pengamatan makroskopik terhadap permukaan
patahan, retakan sekunder dan fenomena
permukaan lainnya.
7. Pengamatan mikroskopik dan analisis permukaan
patahan.

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8. Pemilihan, persiapan, pemeriksaan dan analisis
metalografi.
9. Penentuan mode kegagalan.
10. Analisis kimia terhadap material, produk korosi
permukaan dan deposit atau lapis lindung.
11. Bila memungkinkan lakukan analisis mekanika
perpatahan.
12. Bila memungkinkan lakukan pengujian melalui
simulasi kondisi pemakain.
13. Analisis terhadap keseluruhan data dan fakta yang
diperoleh, membuat kesimpulan berdasarkan data
dan analisis, serta menulis laporan mengenai
analisis kegagalan yang dilakukan.
14. Menindaklanjuti rekomendasi terhadap kegagalan
yang telah dianalisis.
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