Analisa Kegagalan Material

Oleh Miftahul Jannah

Why do We Need to Learn About Failure
Analysis?
1. Kecelakaan RMS Titanic di Samudera Atlantik (1912)

titik A

Impact Force
titik B

Temperature
Misal, pada titik A yaitu pada suhu air berkisar 22 0C, baja memiliki kekuatan impak sebesar
110 KJ sedangkan ketika suhu diturunkan hingga mencapai -2 0C yaitu pada titik B maka
kekuatan impaknya hanya mencapai 20 KJ. Jika es menghantam badan kapal dengan energi
diatas 20 KJ, maka material otomatis akan rusak. Kekuatan turun begitu besar dikarenakan
bentuk kurva yang memiliki bagian dengan kecuraman tinggi sehingga penurunan suhu yang
kecil akan mengakibatkan penurunan energi yang besar.
2. Meledaknya Badan Pesawat pada Penerbangan Aloha 737-297
(1988)

Penyebab utama dari lepasnya badan pesawat adalah

kelelahan logam setelah terjadinya korosi celah (Crevice
Corosion) akibat lingkungan pantai yang memiliki tingkat
salinitas tinggi dan lembab dan diperparah dengan usia
pesawat yang telah mencapai 19 tahun.

Korosi celah adalah korosi yang terjadi pada celah atau

daerah yang dilindungi dari permukaan logam yang
berhubungan dengan lingkungan yang korosif. Contoh
gambar 2
3. Runtuhnya Silver Bridge di West Virginia (1967)

Awal keruntuhan disebabkan karena adanya retakan kecil pada sistem penahan jembatan yang
kemudian berkembang menjadi korosi internal dan lebih lanjut dinamakan korosi tegangan. Lubang
yang terbentuk pada permulaan hanya memiliki kedalaman 2,5 mm dan kemudian rusak dalam tampilan
getas. Pertumbuhan retakan sendiri disebabkan adanya kesalahan manufaktur yang menyebabkan
adanya tegangan residu pada bagian rantai. Pada masa itu, belum ditemukan adanya teknologi yang
mampu mendeteksi cacat pada logam.
4. Runtuhnya Jembatan Kutai Kartanegara (2011)

Prof. Dr. Ir. Bambang Suhendro, MSc, seorang ahli

konstruksi dari Universitas Gajah Mada menyebutkan
penyebab runtuhnya jembatan adalah karena penurunan
kualitas material seiring berjalannya waktu sedangkan
menurut Iswandi Imran, pakar konstruksi dari ITB
menyebutkan bahwa overstress akibat kelebihan muatan
saat dilakukan pengencangan kabel dan adanya
kelelahan (fatigue) dari material merupakan penyebab
dari runtuhnya jembatan.
Then What We Study?
Principles of Failure Analysis :
a. What is Failure? What is Failure Analysis
b. Fundamental Sources of Failure
c. Impact of Failure Analysis on Society
d. Stages of Failure Analysis
Definition of Failure
When a part or device can no
longer perform its intended
function, the part has failed.
Definition of Failure Analysis
A systematic, science-based method
employed for investigation of failures
occurring during tests or in service.
Fundamental Sources of Failure
* Deficiencies in design.
* Deficiencies in the selection of
materials.
* Imperfections in materials.
* Deficiencies in processing.
* Errors in assembly.
* Improper service conditions.
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Impact of Failure Analysis on
Society

* Cost of failure.
* Cost of failure analysis.
* Improvement of products.
14 Stages of Failure Analysis
1. Background data. 8. Metallography
2. Preliminary exam. 9. Failure mode.
3. Nondestructive tests. 10. Chemical analysis.
4. Mechanical tests. 11. Fracture mechanics
5. Sample selection. 12. Simulated tests.
6. Macroscopic exam. 13. Analysis & report.
7. Microscopic exam. 14. Recommendations.

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1. Collection of background data and
samples.

* Manufacturing history. * Inventory of parts.

* Service history. * Abnormal conditions.
* Photographic records. * Sequence of fractures.
* Wreckage analysis. * Sample selection.
Fracture A preceded fracture B.
Fracture A preceded fractures B and C.

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2. Preliminary Examinations.

* Most important part of failure analysis.

* Visual inspection of all parts.
* Detailed photography of all parts.
* Study of the fractures.
3. Non-destructive Inspections.

* Magnetic particle inspection.

* Liquid penetrant inspection.
* Electromagnetic inspection.
* Ultrasonic inspection.
* Radiography.
* Residual stress analysis.
4. Mechanical Testing.

* Hardness testing.
* Tensile testing.
* Shear testing.
* Impact testing.
* Fatigue testing.
* Fracture mechanics testing.
5. Selection and Preservation of Fracture
Surfaces.

* How? Very Carefully!!!

* Prevent chemical damage to samples.
* Prevent mechanical damage to samples.
* Prevent thermal damage to samples.
* Careful cleaning:
Least destructive technique first.
6. Macroscopic Examinations
* Use low power stereo-microscopes.
* Determine Origin of failure.
* Determine direction of crack growth:
Chevron patterns, River marks, beach
marks etc...
* Determine ductile or brittle fracture.
* Locate other cracks.
7. Microscopic Examinations
* Light microscopes:
shallow depth of field.
* Transmission Electron Microscopes (TEM):
sample preparation problems.
* Scanning Electron Microscopes ( SEM):
conductivity problems.
coating and replication techniques.
Dimples typical of a ductile overload fracture by
micro-void coalescence mechanism
Striations typical of fatigue failures
Cleavage fracture typical of brittle overload fracture
Rock candy structure typical of intergranular fracture
8. Metallographic Examination
* Class of Material:
Cast (Cor) or Wrought (Tempa)
* General Microstructure.
* Crack Path (Jalur Retak):
Transgranular (Memotong Butir) and/or Intergranular (Antar batas
butir)
* Heat Treatment Problems:
Decarburization, Alpha-Case, etc….
Lap defect in forging
Interganular crack in copper tube
Crack branching in martensitic steel
9. Failure Modes
* Ductile:
Plastic Deformation
Equiaxed or Shear Dimples
Dull, Gray and usually Transgranular.
* Brittle:
No Macroscopic Plastic Deformation
Cleavage, Intergranular or Striations
Difficult to diagnose.
Modes of Fracture

* Monotonic Overload
Brittle
Ductile
* Sub-Critical Crack Growth
Static Loads
Dynamic Loads
Mechanisms of Fracture
* Overload - Fracture with application of load.
Ductile or Brittle
* Crack Growth - Under Load Over Time.
Fatigue
Stress Corrosion Cracking
Hydrogen Embrittlement
Creep
Sub-Critical Crack Growth under Dynamic
Loads

* Fatigue
* Corrosion Fatigue
* Thermal Fatigue
Sub-Critical Crack Growth under Static
Loads

* Stress Corrosion Cracking

* Hydrogen Embrittlement
* Liquid Metal Embrittlement
* Creep Rupture
Some Common Fractographic
Features
Brittle Overload Cleavage
Ductile Overload Dimples
Stress Corrosion Cracking Intergranular
Hydrogen Embrittlement Intergranular
Creep Rupture Intergranular
Fatigue Striations

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10. Chemical Analysis

* Optical Emission Spectroscopy

* Wet Chemical Analysis
* X-ray, Electron & Neutron Diffraction
* X-ray Fluorescence
* Infrared & Ultraviolet Spectroscopy
* Energy and Wavelength Dispersive X-ray Analysis.
* Surface Analysis Techniques
11. Fracture Mechanics

* Fracture Toughness Testing.

* Strain Rate Sensitivity.
* Notch Sensitivity.
* Triaxiality
12. Simulated-Service Testing

* Of Limited Value.
* Simulated Corrosion Tests.
* Deciding between several possible
mechanisms.
* Errors by Changing Severity of Conditions.
13. Conclusions and Report

* Be Clear & Concise.

* Do not Express Opinions Without Facts.
* Consider the Client.
* Site the Sources of External Data.
* Check list is a good idea.
14. Recommendations

* Should lead to prevention of future failures.

* Should lead to product improvements.
* Do not rush to change material or process
specifications without complete analysis of
possible interaction with other parts of the
system.