Question 3 One of the practical aspects of materials selection in the design, development and production of new components (or

parts/ structures) is the possibility of failure of the component (or parts/ structures) under normal operation.
[Salah satu aspek penting dan praktik pemilihan bahan dalam rekabentuk, pembangunan dan pengeluaran komponen (bahagian/ struktur) baru adalah kemungkinan untuk komponen tersebut gagal semasa operasi biasa.

a) Define the failure of materials or components and give four (4) types of that failure.
Definisikan kegagalan bahan atau komponen dan berikan lima (5) jenis kegagalan tersebut]

[20 marks] Failure is defined as inability of materials or components to i) perform the intended function (3) ii) Meet performance criteria although it may still be operational (3) iii) Perform safely (3) and reliably even after deterioration. (3) Examples i) Fracture (2) ii) Corrosion (2) iii) Wear (2) iv) Yielding (2) v) Buckling (elastic instability) (2) b) Give three (3) primary objectives of failure analysis and from these objectives explain how it can be implemented?
[Berikan tiga (3) objektif primer analisis kegagalan dan daripada objektif ini terangkan bagaimana ianya dilakukan]

[30 marks] There are 3 primary objectives; i) The first objective is to examine the objective evidence presented by the failed components (4) and, from that evidence, determine the failure mechanism (4). ii) The second objective is to determine the primary cause, or what is commonly called the root cause, of the failure (4). This is accomplished by examining design (4) and operational issues (4) to determine what specific factor, or factors, was responsible for the failure (4). iii) The third objective, recommendation of corrective actions that will prevent similar failures, (4) can be accomplished once the root cause of the failure has been identified. (4)

c) A process engineer found a significant pressure drop and realizes one of the plant heat exchanger might have experienced some problem. After several inspections, he found that one of the tubes in the E-1406A heat exchanger was experiences leaking. The tube was then removed and a group of UniMAP final year student was given a task to further investigate this failure problem. According to the daily report made by personnel incharge, the tube side was contains vapor and liquid of hydrochloride acid (HCl), ethylene dichloride (C2H4Cl2), and vinyl chloride monomer (C2H5Cl2), while the shell side contains the flow of untreated cooling water (Figure 1). After some investigation is done, several findings were found; i) The tube side was coated by 25 mm polypropylene ii) The shell side of the tube was covered by brownish deposit layer iii) The tube material was carbon killed steel as stated in plant design. iv) The failure of the tube was resulted by pitting corrosion that initiated from shell side surface. v) No microcracking or branching cracks were observed and it confirms that the failure was not due to overloading or any excessive external stresses on the tube. vi) There are the reductions of the solute atoms in the stainless steel matrix during corrosion attack. vii) Microanalysis at pitting region shows the present of chloride and the failure was believed resulted by untreated cooling water. From the statement above, plan root-caused analysis procedures that should be taken and give reason for each of procedures. Suggest your own recommendation to prevent the future failure.
[Seorang jurutera proses mendapati kejatuhan tekanan yang tinggi dan menyedari salah satu daripada penukar haba logi berkemungkinan telah mengalami masalah. Selepas beberapa pemeriksaan, beliau mendapati salah satu tiub dalam penukar haba E-1406A telah mengalami kebocoran. Mengikut laporan harian yang dibuat oleh kakitangan bertugas, sebelah dalam tiub mengandungi wap dan cecair asid hidroklorik (HCl), etilina diklorik (C2H4Cl2) dan monomer vinil klorida (C2H5Cl2), semetara sebelah luar tiub mengandungi aliran air penyejukan tak terawat (Rajah 1). Tiub tersebut kemudiannya dikeluarkan dan satu kumpulan mahasiswa tahun akhir telah diberi tugas untuk siasatan lanjut masalah kegagalan ini. Setelah siasatan dilakukan, beberapa penemuan telah dijumpai; i) Tiub sebelah dalam disaluti dengan 25 mm polipropilena ii) Tiub sebelah luar diselaputi dengan lapisan mendakan keperangan iii) Bahan tiub adalah keluli carbon termati seperti yang dinyatakan dalam rekabentuk logi iv) Kegagalan tiub adalah disebabkan oleh kakisan lubang yang bermula daripada permukaan sebelah luar v) Tiada mikrorekahan atau rekahan cambah diperhatikan pada mikrostruktur tiub dan mengesahkan bahawa kegagalan tidak disebabkan oleh lebihan berat atau kewujudan tekanan luar pada tiub vi) Terdapat penurunan atom-atom terlarut dalam matriks keluli kalis karat semasa serangan kakisan. vii) Mikroanalisis pada rantau lubang menunjukkan kehadiran klorida dan kegagalan adalah dipercayai disebabkan oleh air penyejukan tak terawat. Daripada pernyataan di atas, rancang prosedur-prosedur analisis punca-penyebab yang sepatutnya diambil dan berikan alasan untuk setiap prosedur. Cadangkan tindakan pencegahan untuk mengelakkan kegagalan sama di masa hadapan.]

Figure 1: Schematic diagram shows the pitting corrosion on the heat exchanger tube. [50 marks]
Procedures 1) Obtaining background data 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. 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.

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

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)

7) Determination of failure mechanism & recommendations

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.

Question 2 A wide variety of factors can lead to the failure of a component or system. The sources of failure fall into one of four basic categories such as deficiencies in design, poor in materials, service conditions that have been modified from those considered in design, and errors in assembly or maintenance.
[Pelbagai faktor boleh menyebabkan kegagalan pada sesuatu komponen atau system. Punca kegagalan terbahagi kepada empat (4) ketegori asas seperti kecacatan rekabentuk, kelemahan pemilihan bahan, keadaan servis yang telah diubahsuai daripada yang diambilkira dalam rekabentuk dan kesilapan pemasangan semula atau penyelengaraan]

a) In fracture failure, ductile and brittle fractures are based on the ability of a material to experience plastic deformation.
[Dalam kegagalan patahan, patahan mulur dan rapuh adalah berasaskan kepada kebolehan bahan untuk mengalami canggaan palstik.]

i) Differentiate between ductile and brittle fracture.

[Bezakan patahan mulur dan rapuh.]

ii) Explain the three (3) stages in the ductile fracture of a metal and describe the evolution of that ductile failure
[Terangkan tiga (3) peringkat dalam patahan mulur logam dan gambarkan evolusi patahan mulur tersebut.]

iii) Visual observation, optical microscope and scanning electron microscope are three (3) major tools that play an important role in determining the success of a

root-caused analysis. Explain the each their roles in determining the (a) ductile and (b) brittle failure
[Pemerhatian mata kasar, mikroskop optik dan mikroskop elektron imbasan adalah tiga (3) alat utama yang memainkan peranan penting dalam menentukan kejayaan analisis puncapenyebab. Terangkan peranan setiap alat tersebut dalam patahan mulur dan rapuh]

[45 marks] i)
Ductile fracture Plastic deformation (1) High energy absorption before fracture (1) Characterized by slow crack propagation (1) Detectable failure (1) Stable crack (1) Eg: Metals, polymers (2) Brittle fracture Small/ no plastic deformation (1) Low energy absorption before fracture (1) Characterized by rapid crack propagation (1) Unexpected failure (1) Unstable crack (1) Eg: Ceramics, polymers (2)

14 ii) The process of fracture: The specimen elongates (1), forming a necked region (1) in which cavities form. The cavities coalesce (1) in the neck center, forming a crack (1) which propagates toward the specimen surface in a direction perpendicular to the applied stress. As the crack approaches the surface, its growth direction shifts to 45 (1) with respect to the tension axis. This redirection allows for the formation of the cup-and-cone (1) configuration and facilitates fracture. 6

12
Ductile Fracture Visual Observation - Necking or plastic deformation (1) - Dull (1) and fibrous fracture surface (1) - Shear lips (1) Optical Microscopic - Plastic distortion of grains (1) - Irregular trans-granular fracture(1) SEM Microscopic - Micro-voids elongation in direction of load (1) - Singular crack with limited/no branching (1) Brittle Fracture Visual Observation - Little/no plastic deformation (1) - Shiny, course, crystalline fracture surface (1) - Chevrons (1) Optical Microscopic - Minimal deformation (1) - Inter-granular or trans-granular (1) SEM Microscopic - Cleavage or inter-granular (1) - Discontinuity or stress riser at origin (1)

15 d) In term of design, describe or explain the methods to control corrosion failure [30 marks] Allow for the penetration action of corrosion along with the mechanical strength requirements when determining the appropriate metal thickness (2) Weld rather than rivet containers to reduce crevice corrosion (2). If rivets are used, choose a rivet material that is cathodic to the materials being joined (2). If possible, use galvanically similar metals for the entire structure (2). Avoid

i) ii) iii)

iv)

v) vi) vii) viii)

dissimilar metals that can cause galvanic corrosion(2). If galvanically dissimilar metals are bolted together, separate them with nonmetallic gaskets and washers (2). Avoid excessive stress and stress concentrations in corrosive environments to prevent stress-corrosion cracking (2), especially when using susceptible materials such as stainless steels and brasses. Avoid sharp bends in piping systems to prevent erosion corrosion (2). Design tanks and other containers for easy draining and cleaning (2). Design systems for easy removal and replacement of parts that are expected to fail in service, such as pumps in chemical plants (2). Design heating systems such that hot spots do not occur (2).