Material Failures

Sharing Knowledge
Engineering Forum – 27 Nov 2015
Prepared by :
Eki Budi Fatari (1108040)
1

Material Selection Steps

(by : George Dieter & Linda Schmidt “Engineering Design”- Mc Graw-Hill, 5th edition)

Define Material
Compare with
Define Function Manufacturing candidate Detail
database
Parameter investigation

•Define design performa •Amount of parts wil be •Screening properties •Cost & material price
produced
•Translate into related •Eleminates which can •Fabrication ability
physical properties •Dimension & not fit the
complexity perform/design •Grade availability
requirement
•Tolerances required & •Computer modelling
surface finishing

•Manufacturability :
how to make the size
required, joint
mechanism, etc
2

Design Function
(Requirement Analysis)

Free variable
Define Design performa

Function Constraint Objective

design

Support beban? Cost must be under Murah? Bentuk tipis?

$..
Menahan pressure? Ringan? Bentuk bulat?
Operate in 2000 C
Transmisi Panas? Kuat? etc
etc
etc

Materials Evaluation :
- Physical Properties,
- Economical Properties,
- Environment Properties
Translate into Related Physical

Strength Cost/kg Cost/kg Section area

properties

Stiffness Melting point Density Z modulus

Young modulus Corrosion rate Daur Material

Thermal Corrosion
conductivity resistance

Thermal expansion Service

temperature range
3

Material selections means ...

the sensitive physical properties of a material in order to be

To evaluate
used for any purposes which fit with its objective and design constraint

Thermal

Magnetism Electrical
Physical
Properties
of
Materials

Optical Mechanical Failure Analysis related

to Structural design
 Physical (mechanical) properties
4

Mechanical Properties of
Materials

Young Fracture Endurance

Hardness Ductility Strength Corrosion
Modulus Toughness Limit

Yield

Tensile

Deformation Fracture Fatigue

Elastic
Plastic Deformation
Deformation

Failure of Materials

Fracture Mechanics
 Definition
5

Deformation
is the response by a material due to application of external forces

Young Modulus
Is a mechanical property of linear
elastic solid materials, and it shows
the slope of response which is
related to external force and its
deformation

Ductile
Tendency of materials and its ability
to resist the crack phenomenon
𝜎=𝑬∈
Ductility
Intrinsic property of materials that
provide information about plastic
deformation which can be retained
before fracture

Hardness
Is a measure of resistance of material to occurence of Localized Plastic Deformation
 Definition
6

3 states of probability related to External Forces :

- Elastic Deformation  Temporary

- Plastic Deformation  Permanent  Occurs when Stress > Yield Strength
- Necking & Fracture  Permanent  Occurs when Stress > Tensile Strength

Strength

Yield Strength is a mechanical property of

materials that show its resistance againts
plastic deformation
necking
Yield
Strength Tensile Tensile Strength is a mechanical property
Strength of materials that show the peak
performance and its resistance to external
stress before necking
 Definition
7

Fracture toughness (Kic) is a measure of the material resistance to

crack propagation

High value of Fracture Toughness,

means the material is more resistant to the occurrence of brittle
fracture

Sample Ductile Fracture Sample Brittle Fracture

 Fracture Toughness Values
8
 Failures
9

Failure is defined as a condition when a material is not able to withstand the external force,
so there occurs phenomenon of broken or separation

Failure

Fracture Fatigue Corrosion

Crack growth Corrosion rate

Crack propagation

Fracture toughness (Kic) Fatigue Threshold (DKth) Galvanic Series

Endurance Limit

Paris Law Constant

material resistance to crack
propagation

Knowledge of the value of fracture toughness
material becomes necessary for an engineer to make
calculations on the maximum limit size of the
crack is still allowed to be used on a structure
of service condition after the inspection process is
done.
Stress intensity factor is a quantity that is a
Stress Intensity Factor function of loading (loading),
the size of the crack (crack size) and
𝐾 = 𝑌𝜎 √𝜋𝑎 the geometry of the structure.

Because it is very difficult to create a Engineering Disciplines of

structure that is free of defects. Non Destructive Test Crack size (a)
 Fractures
10

Contoh sederhana :
untuk memahami yang mana yang dimaksud dengan Fracture Toughness, dan yang mana yang
dimaksud dengan Stress-intensity factor bisa dianalogikan pada contoh sederhana berikut :

Jika suatu material mengalami pembebanan, maka material tersebut dapat dihitung nilai
Stress-Intensity yang dialaminya (𝑲𝟏) .

Pada saat yang bersamaan, material tersebut juga memiliki suatu nilai sifat intrinsik material
yang disebut sebagai Fracture Toughness (𝑲𝑰𝒄) .

𝐾1 ≥ 𝐾𝐼𝑐 or a > ac  Fracture

𝐾𝐼𝐶 ≥ 𝐾1 𝑜𝑟 𝑎 < 𝑎𝑐  Crack Will not propagate

𝑆𝑡𝑟𝑒𝑠𝑠 𝑑𝑖𝑎𝑙𝑎𝑚𝑖 (𝜎) Calculate

Stress Intensity Factor

𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝐶𝑟𝑎𝑐𝑘 𝑠𝑖𝑧𝑒 (𝑎) (Mode I) Fracture
Compare Toughness
𝐾1 = 𝑌𝜎 √𝜋𝑎 (Kic)

𝐺𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 (𝑌)

It means :
When the cracks present in the structure, and reach the maximum allowable crack (a max),
the structure will be Fracture “Failure” eventough the Stress has not reach the
Tensile Strength

IMPORTANT to measure
the Crack Size
 Fractures case
11

Sample Case :

Estimate the size of the defect that will be responsible for the failure on a
structure made of a titanium alloy material (Ti-6Al-4V)
if the structure is applied to the stress level of 650 MPa (still below the Yield, 910 Mpa) !

Solution :
- Check datasheet for fracture toughness of Titanium alloy (Ti-6Al-4V)
- Calculate the approximation of calculation for maximum allowable crack size “a”

1 𝐾𝑖𝑐
𝑎= ^2
𝜋𝑌 𝜎

K1c = 55 Mpa-m1/2
1 55 𝑀𝑝𝑎 𝑚^0.5
s = 650 Mpa 𝑎 = 3,14∗1 650 𝑀𝑝𝑎
^2
Geometry constant, use approximation
Y=1 𝑎 = 0,0023 𝑚 = 2,3 𝑚𝑚
for crack size (a) << material thickness

This Crack Size can be a cause of Failure if present in the Structure

So, the Inspector (use Non Destructive Test) must

filter the structure to avoid crack size of 2,3mm

a  Crack Tolerant (Damage tolerant)

 Fatigue
12

Fatigue is the Weakening of material subject to the fluctuations (repetitive)

stress and dynamic stress (eg, bridges, aircraft, engine components, etc).

Fatigue  PREMATURE FAILURE when stress has not exceeded the tensile
strength, after pass number of loading cycles.

Fatigue Strength
Fatigue Material
Response

Has Endurance No
Limit Endurance Limit

Fatigue Strength down until

Endurance Limit (fatigue limit) Fatigue Strength down
as function of cyclic loading without Endurance Limit

Exp: Steel, Iron,

Exp: Aluminum,
Copper
 SN Curves
13

A graph showing Stress as a function of number of Cycle

Fatigue Strength  function of Cycles

Fatigue Limit = Endurance Limit

International Convention ,
Number of Cycles is 107
 Fatigue Strength Values
14

(Endurance Limit)

Failure when
Stress not reach
Stress > Endurance Limit the Tensile
Strength
(after 10^7 loading cycles )

IMPORTANT :
So, theoritically the Structure will NEVER MEET the FAILURE when the Operational
Stress in the structure always below the Endurance limit  Infinite Life
 Fatigue Process
15

Phase 1 : Phase 2 : Phase 3 :

Crack Intitiation Crack Growth Final Failure

Critical Crack Size

(ac)

Paris-Erdogan equation

III

I II
Pertumbuhan striation

DKth

DK = Cyclic Stress Intensity

DKth = Threshold Stress Intensity Range
DK < DKth  NO CRACK GROWTH
16

Paris-Erdogan equation

III
`

I II
Pertumbuhan striation

Critical Crack Size (ac)  Unstable crack

 Stress Cycles
17

Decrease Mean Stress,

Fatigue Limit Increase

Improving Fatigue Life

(Fatigue Strength) by
Induce residual compressive
stress
Exp : Shot peening
 Fatigue Approximation ;
18

Crack Growth (Phase 2 , Paris-Erdogan Law)

Life of a structural
component related to
the rate of crack growth
DK  Cyclic Stress Intensity

da/dN  Crack Growth Speed

ai = inspected crack size

ac = theoretical stress assumed
DK = Kmax–Kmin  Stress Intensity range
Y = geometrical Constant

C & m are Paris Constant* (intrinsic material properties)

Fatigue Life
“Number of Cycle
The material constants C and m can be
found in literature or by performing tests
to cause failure”
(ASTM E647 sets guidelines for these tests)

*Fatigue by David Roylance - MIT

 Paris Constant Value
19

C C
m
20

By Prof. Subra Suresh

 Fatigue Case
21

Sample Case :

A Pressure vessel tank with operating design 90 Mpa was inspected.

Estimate , how long the structure can accomodate the operational pressure before
the fatigue grew to an unstable crack when inspector found 10 mm crack size in
longitudinal joint !! (from literature

Data :
Kic = 45 MPa√m

Assume geometrical constant Y = 1.1

 Fatigue Case
22

Solution :
- Check datasheet for fracture toughness of Steel used  Kic = 45 MPa√m

- Calculate the ac

- Then calculate Nf , using ai = 10 mm

𝑎𝑐 = 65,7 𝑚𝑚
𝑵𝒇 = 𝟐, 𝟐𝟓 𝒙 𝟏𝟎𝟓 𝑪𝒚𝒄𝒍𝒆𝒔

operating design = 90 Mpa

 Fatigue Case
23

To Avoid the Fatigue failure, we have to minimize the souce of Cyclic Stress
 Improve Fatigue Life & Residual Stress
24

Residual Stress

To Decrease

Fatigue Life
(Fatigue Strength)
Increase
 Influence of Welding Sequence to
25

Residual Stress
Source : Teknologi Pengelasan Logam
– Prof. Dr. Harsono W. & Prof Dr. Toshie Okumura (Bab 5 - p. 143)

Lowest
Residual Stress

Welding Sequence
is
Important
 Improve Fatigue Life & Residual Stress
26

Advantage : On the spot (location)

 Residual Stress Measurement
27
 Residual Stress Management
28
 Failures
29

Influence of Heat Affected Zone

Steel Yield Strength = 60 kg/mm2 Steel Yield Strength = 80 kg/mm2

 Failure due to Corrosion
30

Hydrogen induced Thermo Galvanic

corrosion 2% Others
1% 4%
Selective Corrosion
1%

Crevice Corrosion
2%
Korosi uniform
Errosion & 32%
Cavitation
9%

Pitting
Corrosion
Intergranullar 16% SCC
10% 23%

Data persentase kerusakan

oleh korosi berdasarkan
bentuk terjadinya korosinya
31

Reduce stress concentrator

32

Reduce stress concentrator

 Improvement Room
33

To
Strengthen the
Inspector Competency
for NDT & its instrument
To be more careful in
To define Welding process ,
Maximum Allowable Crack use the Sequence to
(Damage Tolerant) minimize the Residual
Stress

To
Approximate nearest
Fatigue Life of Product
To optimizing present
(Nf)
Tools for Removing the
Residual Stress

To
Evaluate Designs &
Process to Avoid the To measure
Fatigue problem the Residual Stress
after Welding

To Minimize Residual
Stress using Latest
Technology : in situ
Stress Reliefing