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Question 4

(EBT 423)

Local universities graduates are encouraged to take parts in business opportunity in Malaysia. As materials engineering graduate, knowledge and skills in failure analysis seems having a large potential to be commercialised internationally. To set up a consultation firm that specialist in failure analysis services of engineering materials, you have to apply RM500,000 from Graduate Entrepreneur Schemes. To realize this intention, you have to make a proposal based on following inquiries.

a)

Explain the definition of failure in term of materials engineering? [10 Marks]

Inability of a materials or a components to 1. perform the intended function 2. Meet performance criteria although it may still be operational 3. Perform safely and reliably even after deterioration. Examples 1. Yielding 2. Wear 3. Buckling (elastic instability) 4. corrosion 5. fracture

b)

In term of economy, convince the Graduate Entrepreneur Schemes evaluation committee panels on the important and the value of failure analysis that will be offered to potential industry customers. [40 Marks] Identify corrective actions based on a determination of the root cause of the failure. Minimize future failures of the same type. Tool that can be used to reduce maintenance costs, increase system availability, reduce the potential losses involved in catastrophic failures. Potential savings will vary on a case by case basis. Used to identify the party at fault. Financial losses resulting from a failure can often be recovered when deficiencies in design, workmanship or materials can be identified as the root cause of the failure. In your proposal, list down and justify the procurement of the scientific equipments that necessitate to purchased to implement failure analysis consultation services [30 Marks] 1) Photography 2) Optical Microscopy up to 600X 3) Scanning Electron Microscopy (SEM) over 10,000X 4) Chemical Analysis SEM/EDS Spark Emission Spectroscopy Fourier Transform Infra Red (FTIR) 5) Mechanical Testing Hardness, micro-hardness, tensile, shear, physical testing 6) Stress Analysis / FEA Magnitude, principal direction, sensitivity 7) Instrumentation Strain Gages, accelerometers, thermocouples, ect.

c)

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8) Non-Destructive Testing (NDT)

(EBT 423)

d)

Recommend the types of potential industries that needs your consultation services [20 Marks] 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Upstream and Downstream Oil & Gas Petrochemical Refining Power generation Marine Medical Instruments Commercial Properties Government Agency Alloy Producers Equipment Manufacturers Ship and Ship Building Water and Wastewater

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(EBT 423)

Question 5 A new car user heard a significant weird noise from engine part. After several inspections at authorised workshop, a mechanic found that the engine starter gear was abnormally functioning. The gear was removed and sent to UniMAP Materials Laboratory for further investigation. After some inspections by staff incharged, it were found the gear was experiences transgranular fracture and there are with some branching cracks at the end of single large crack at gear teeth as shown in Figure 2. Technical report stated that the failure was occurred resulted by internal stress originally from casting defect.

Figure 2: Schematic diagram shows the failed starter gear component [Rajah 2: Gambarajah skema menunjukkan komponen gear pemula gagal]

a)

From the above statement, explains in detail the root cause of the gear failure. [20 Marks]

Defect in casting and are caused by hot tearing or hot cracking A hot tear is a fracture formed during solidification because of hindered contraction A hot crack is a crack formed during cooling after solidification because of internal stresses developed in the casting

b)

If you are appointed to investigate this case, plan root-caused analysis procedures that should be taken and give reason for each of procedures. [60 marks] Procedures Reason To investigate the basic information including its location, manufacturer, function of component, operational condition, maintenance and cleaning history as well as opinions of related personnel that possible to be a primary clue of the root cause analysis.

1) Obtaining background data

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2) Visual examination followed by closed-up photographs by digital camera.

(EBT 423)

3) Chemical composition analysis by using XRF or spark emission spectrometer

5) Metallographic examination by optical microscope. i) As-polished microstructure ii) Etched microstructure Prior to metallographic viewing, there are several works need to carried out such as cutting, sectioning, mounting, grinding, polishing & etching. 6) Fractographis analysis (SEM) and microanalysis (EDS)

The as-received photographs provide an archival record of the original condition of the failed component prior to cutting and sectioning Also provide an effective place to indicate the locations from which the various samples used in the destructive examination were obtained. In this case, visual examination found the failed tube was experiences pitting corrosion which exhibited by large transverse cracks, holes and pitting profile. Analysis of the chemical composition of the component is a routine part of a failure analysis The analysis is used either to determine if the material meets the specified composition limits. In this case, heat exchanger tube materials is meets the specified composition limits of 316L stainless steel. In as-polished condition, the presence of defects such as inclusions and voids or microstructural anomalies at the crack initiation site is examined. In this case, as-polished microstructure is presented to investigate the direction pitting attack whether it comes from tube side or shell side. In this case, pitting corrosion from shell side. Specific etchant has to be developed to delineate specific microstructural features. Once etched, the microstructure of the material can be determined and the relationship between the microstructure and the damage can be examined. In this case, no transgranular or intergranular microcracking is detected. Hence, the failure is not due to overloading or any excessive external stresses on the tube. SEM analysis is carried out to identify of the fine scale features fracture mode. However in this case, no plastic deformation were observed and the surface fracture shows the tube material is ductile. It confirms that the failure is not due to overloading or any excessive external stresses on the tube. Identification of the chemical species present in the corrosion deposits plays a critical role in identifying the root cause of the corrosion and in this case, the present of chloride element in EDS result is strongly believed result by untreated that used as a coolent. Without identification of the failure mechanism, it is usually impossible to determine the root cause of the failure, which forms the basis for recommendations for immediate action whether the components should be replaced or not and to eliminate or reduce the frequency of future failures. Determination of the failure mechanism is considered a critical step in the failure investigation. In this particular case, the failure was caused by the occurrence of temperature gradient on the tube.

7) Determination of failure mechanism & recommendations

c)

Recommend the preventive action that should be taken to avoid this failure. [20 Marks]

improve casting procedure Heat treatment to reduce residual stress Mould preheating before pouring

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Proper materials selection

(EBT 423)

Question 6 A process engineer responsible for the operation of petrochemical plant noticed a significant pressure drop which indicates that the boiler tubes might have experienced some damage problem. Primary report by inspection engineers found that the water content in steam tanks was reduced by as much as 15%. There are the some pitting marks were observed at tensioned side at the bend area of the boiler tube (Figure 3). This pitting results the vaporising out of water vapour. Chemical composition analysed by spark emission spectrometer was shown in Table 1. Table 1: Chemical Composition [Jadual 1: Komposisi Kimia] Weight (%) Corrosion Element Failed Resistance Materials Steel (standard) C 0.015 Max: 0.08 Si 0.449 Max: 0.75 Mn 2.004 Max: 2.0 Cr 17.585 16 ~ 18 P 0.0285 0 ~ 0.045 S 0.0033 Max: 0.03 Ni 11.911 10 ~ 14 Mo 0.396 2~3

Figure 3: Bend tube [Rajah 3: Tiub bengkok]

a)

From the above statement, what your hypothesis about root causes of tube failure and justify your reason. [30 Marks] Residual stress resulted from bending works Corrosion attacks originate from water, believed resulted from application of untreated water Lower content of Mo (lower pitting index no.) contributes to pitting corrosion All of the above factors contribute to the stress corrosion cracking (SCC). To initiate the failure investigation, you have to make a site visit to that petrochemical plant. Identify the important information needed from plant engineers that help you getting some primary clues which determines your investigation direction. [40 Marks] Location, name, 12. Type of materials (Chemical composition) P/N, 13. Operational documentation (standard, Description, temp./ pressure etc) Manufacturer or fabricator 14. Service deviations

1. 2.

3. 4. b)

1. 2. 3. 4. 5.

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6. 7. 8. 9. 10. 11. Function of item Maintenance procedures Maintenance history Cleaning procedures Cleaning history Operational procedures (temp./ pressure etc)

6
15. 16. 17. 18. 19. 20. 21.

(EBT 423)
Normal stress orientations Extent of incident Precipitating events Drawings photographs Previous inspections reports, Opinions of related personnel

c)

Calculate the tube pitting index number and recommend the new materials that capable to prevent the same future failure. [30 Marks] Pitting Index (PI) = wt.% Cr + (3.3)(wt.% Mo) = 17.585 + 3.3(0.396) = 18.89 Further upgrades are out of the realm of the stainless steels and into high-alloys steel. Eg Pitting resistance metals such as high-molybdenum SS. Monel. Incoloys, Inconels, or Hastelloys