Failure Analysis ofPitching Wirefor Low SpeedWind Tunnel(LSW1) (Yusuf Afandi 30-33)

FAILURE ANALYSIS OF PITCHING WIRE FOR LOW SPEED WIND TUNNEL (LSWT)
Yusuf Afandr, A.D. Wiyono1, and M.Danr
lUPT-LUK BPPTEKNOLOGI, KawasanPUSPIPTEK Serpong 2p3IB-BATAN, Kawasan PUSPIPTEKSerpong

ABSTRACT
FAILURE ANALYSIS OF PITCHING WIRE FOR LOW SPEED WIND TUNNEL (LSWT). Pitching wire using one of support component in the aircraft model test for low speedwind tunnel (LSWT). It have operated six months, pitching wire failed through it was testing in the LSWT. To determine the causedwas conducted fraktography examination by stereo mikroskop and scanning electron microscope (SEM), metallography by metalloplan microscope, tensile test by UPM 1000, and hardness test by Frank Finotest had been crried out. Visually in fracture area was found necking before fracture. Macroscopically the characteristic of surface fracture is ductile fracture caused by static tensile stresses.Under scanning electron microscope (SEM), the surface fracture showed silky texture, fibrous, and dimples, as well as matte texture. The microstructure showed fine pearlite and deformation ferrite as result during cold drawing in wire manufacturing. The microstructures have lamellar and globular oxide inclusion. Based on surface fracture characteristic,the failed pitching wire caused by applied tensile stress exceeded maximum tensile stresses;although the mechanical properties of pitching wire conform with piano wire grade B (J1S 3522) is 206 kgimm2.

ABSTRAK
ANALISIS KERUSAKAN PITCHING WIRE PADA LOW SPEED WIND TUNNEL (LSWT). Pitching wire dipergunakan sebagaisalah satu komponen penunjang dalam pengujian model pesawatterbang di dalam Low Speed Wind Tunnel (LSWT). Setelah6 (enam)bulan pemakaian,pitching wire putus pada saatpengujian model pesawatterbang berlangsungdi dalam LSWT. Untuk menentukan sumber penyebabkerusakan dilakukan pemeriksaanfraktografi dengan stereo mikroskop clanScaning Electron Microscope (SEM), Pemeriksaanmetalografi dengan mikroskop metaloplant, uji tarik dengan mesin UPM 1000, clanuji kekerasandengan mesin Frank Finotest. Secaravisual di daerah patahanmemperlihatkan adanya pengecilanpenampang (necking) sebelum patah. Secara makroskopi permukaan patahan menunjukkan ciri khas dari patah ulet (ductile fracture) akibat tegangan tarik statis. Melalui SEM, permukaan patahan memperlihatkan silky texture, fibrous, clan dimples, di samping matte texture. Mikrostrukturnya memperlihatkan adanya perlit halus clan fecit dalam keadaan terdeformasi akibat cold drawing selama proses pembuatanwire. Di dalam mikrostruktur wire mengandunginklusi oksida bentukmemanjangmaupunbentuk membulat. Berdasarkan ciri permukaan patahan, pitching wire mengalami patah karena tegangan tarik statis yang diterima melampaui tegangan tarik maksimum; meskipun sifat mekanis pitching wire memenuhui syarat sebagaipiano wire menurut JIS G 3522 yaitu 206 kg/mm2.

1. INTRODUCTION
Some engine simulation tests for commuter aircrafts have been carried out in Low SpeedWind Tunnel (LSWT), as full or half -model. A neo-classical method has beenimplemented in Low SpeedWind Tunnel, however in an engine test certain characteristics should be identified. The aerodynamic loads were measured by means of a wire supporting system. Strain gauges measured any change in tension of the wires, and produced the corresponding change in aerodynamic loads,ie. Lift, drag and pitching moment [1] . A pitching wire having a diameter of 2.50 mm (figure 1) of piano wire category was used as one of supporting components in an aircraft model testing in a low speedwind tunnel (LSWT) having been used for 6 months, the pitching wire broke down during the aircraft model testing in low speedwind tunnel. The location of break down is shown in figure I and 3. When the LSWT is not in operation, the pitching wire receives a statis load of 200 kg. It was faced with a static test with a constant load of 500 kg for 24 hours. It did not experience deformation nor fracture.

2. TESTING METHOD AND DATA

The pitching wire (Figure I) was sentto the laboratory to be analysed. The analysis includes fractography, metalography, tensile test and hardness test.

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Figure 4. On the shearlip surfaceshowsslip traces.

~,"r_-:~~_,_.,.c~

,
Figure 5. Microfractographshows longitudinal dimple at the surface fracture center

Figure 2. The fracture area shows plastic deformation, samples are taken from location 1,2, and 3.

Figure 6. Microfractograph of the fracture surface shows matte texture combinations and deformation dimple. Figure 3. The surface of pitching wire fracture shows ductile fracture with smooth surface and ductile fracture

has shear plane

2.1.Fractography

A Visual inspectionthe fracture area showsa necking process beforebreakdown. By using SEM at low magnification.The caracacteristics of the fracture surfacecanbe observed asfollows: 1. Plasticdeformation occured prior to fracture 2.2. Metallography 2. Neckingprocess at fracture(Figure3) 3. Shear lips (slantfracture)wasvisible atthe end of For metallographic analysis purposes.Three long thefracturearea(Figure4 area) cuts were taken from the fracture area and nearby 4. The fracture surfaceshowedsilky texture,fibrous location,a.e. 6 hour position (Figure 2). Sample no 1 anddimple (Figure 5)a partfrom beside mattetex-

ture (Figure 6) At a relatively high magnification, the fracture surface of the pitching wire shows the following. 1. The exsistenceof slip fracture on the shear lips surface (Figure 4) 2. The existence of a dimple (Figure 5), especially at the middle of stretching; The fracture, beside matte texture (Figure 6).

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Failure Analysis ofPitching Wirefor Low SpeedWind Tunnel(LSW1) (Yusuf Afandi 30-33)

showed a reduction of cross sectional area (necking prosess)before total break down ocCured. Inclusion of other metals were visible on the fracture surface. In addition a secondarycrack, starting from the outer surface of the pitching wire was found. Its microstructure, fine perlit and ferrit, suffered from the formation due to cold drawing (Figure 7) during wire manufacturing process.

2.4. HardnessTest
The three samples (1,2,3) which have been analysedmettaloraphically were testedfor their hardness.The meanresultswere shownon the Table2.
Table 2. Hardness mean value of pitching wire

3. DISCUSSION
.Based on the visible fracture characteristics (Figure 2), the macro metallography (Figures 7 & 8), it can be said that a pitching wire break down is due to a static tensils stress. The wire experienced the stress is greater than the yield stress. The pitching wire thus, enters plastic period mechanical metallurgically. Hence the wire break down, at 206 kgimm2 tensile stress,stress with a necking was occured before fracture and its fracture surface shows a shear lip2, as shown on Figure 4. The break down can be classified as ductile fracture [3], compare with a scematic ideal fracture due to a static load. Metallographically, necking was occured before break down as clearly visible (Figure 7 dan 8). The presence of other metal inclusion on the fracture surface and secondary crack [4] does not contribute to pitching wire break down. The metal inclusion and secondary crack are assumed to occure after wire break down. When datached from the copper plate,the tip of the fracture area (Figure 2) has a friction or a collision against other surrounding metal. The existence of shear lip on the fracture surface confirms the indication of ductile fracture due to tensile stress. Pitching wire microstructure hasthe shapeoffine pearlite and ferrite with a defonl1edstructure due to cold drawing process during wire manufacturing process. Along or sperical oxide-inclusionwas found atthe middle! inner microstructure (Figure 7 and 8). The oxide inclusion contributes to the occuuence of fracture. Based on the tensile test, pitching wire meetsthe requirement for piano wire according to lIS G 3522 (grade B). The difference in the HV between fracture area (556 HV & 559 HV) and outside fracture area (461 HV) indicate a strain hardening due to shaping process (joinning a circle) in addition to tensile stress during LSWT operation. Based on the above HV difference, the location of break down is estimated to be outside and close to or around the copper plateshole. There is not evidenceoffatigue fracture nor brittle fracture due to shock loading, therefore it can be ignored.

Figure 7. Microsructure of the wire is fine pearlite and ferrite, suffered from deformation due to cold-drawing during wire manufacturing process. The wire inner microstructure contained oxide-inclusion. (Magnification 1000 X; Nital Etching)

Sample no 2 showed fine pearlite and ferrite being deformed due to cold drawing during wire manufacturing process.The wire inner microstructure (within the nuclei) contained oxide inclusion (Figure 8).

Figure 8. Microsructureof the wire is similar to figure 7. (Magnification 1000 X; Nital Etching)

2.3. Tensiles Test

Based on the tensiles test were conductedto threepitching wire samples sufferingfrom breakdown, having beenusedfor 6 months. A comparison betwenthe tensils test meanresult and the standard is shownon Table1.

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4. CONCLUSION
Based on the results of visual inspection, macrofractography and metallography analysis, and tensile test and hardness tests, conclusions can be deduced as follows: 1. A pitching wire break down suffering from a tensile stress greater than its mechanical properties [5], a tensile stress of 206 kgimm2 and a yield stress of 185kgimrn2. A pitching wire break down is classified as ductile fracture due to static tensile stress. A normal pitching wire microstructure and the existence of oxide inclusion within the wire do not contribute to the occurrence of fracture. A pitching wire has a mechanical property (tensile strength) suitable for grade B piano wire according to ns G 3522. Other metals inclusion in one of fracture surfacesis due to friction/collision against other metals when the wire breaks down and datachesfrom the copperplate. There is not evidence that pitching wire break down is due to either fatigue or shock loading.

5. ACKNOWLEDGEMENTS
The authors are grateful to Tri Wibowo,Dr and Wibawa Purabaya M.Eng for contribution, and thank Mr. Sutarjo and Mr. Aswandi for their collaboration.

6. REFERENCES
[1]. Proceedings,The 2nd International Symposium on Aeronautical Science & Technology in Indonesia, Volume 1, Jakarta,page 118and 855 [2]. Metals Handbook, Failure Analysis and Prevention Vol. 10. American Society for Metals,1975 [3]. GEORGE E. DIETER Mechanical Metallurgy, 1986, McGraw-Hill Book Company. [4]. CHARLIER BROOKS, ASHOKCHOUNDHURY, Metaalugical Failure Analysis, 1993,United States of America, McGraw-Hill, Inc. [5]. SHIN-ICHl NISHIDA DR.ENG., Failure Analysis in Engineering Application, 40-41, 1986, Tokyo, Butterworth-Heinemann Ltd, Tokyo, pp. 40-41

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