Material & Metalurgi

Discontinuities & Defects

Dr. Agung Purniawan, ST. M.Eng
 Discontinuities & Defects
• Inherent Defects (Raw Material)
• Fabrication Defects: design, material selection, machining
faults
• In-service defects: corrosion, erosion, wear, wrong loading,
fatigue, creep
• Assembly Defects: unbalance , misalignment , looseness ,
etc.

07-Sep-17 Slide - 2
 Definitions

• Discontinuity: interruption in the properties of the material

under investigation.
• Defect: is a discontinuity that affects the end use of the part
to be investigated.

“Thus all defects are discontinuities, but not all

discontinuities are considered defects”
07-Sep-17 Slide - 3
 Inherent defects
• Defects that appear in the ingot or in the billet before
fabrication:
• Cracks
• Porosity
• Non-metallic inclusions

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07-Sep-17 Slide - 5
 Fabrication defects

Primary Secondary
• Rolling • Seamless tubes
• Casting • Grinding
• Forging • Fatigue cracks
• Welding • Welded pipes
• Extrusion
• Heat treatment

07-Sep-17 Slide - 6
 Rolling defects
• Laminations
• Stringers
• Seams

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 Rolling defects

07-Sep-17 Slide - 8
 Rolling defects

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 Forging discontinuities
• Forging laps
• Forging bursts
• Cracks

Forging bursts Forging laps

07-Sep-17 Slide - 10
 Casting defects
• Cracks
• Porosity
• Cold shut
• Hot tears
• Shrinkage cavity
• Micro shrinkage
• Blow holes

07-Sep-17 Slide - 11
 Casting defects

Hot tears

07-Sep-17 Slide - 12
 Casting defects

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 Definition of welding terms

07-Sep-17 Slide - 14
 Welding defects
• Cracks: crater cracks – stress cracks
• Porosity
• Lack of penetration
• Lack of fusion
• Slag inclusion
• Undercut

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 Welding cracks

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 Stress cracks

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 Collective welding defects

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 Collective welding defects

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 Seams in welded pipes

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 Sludge in extruded pipes

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 Grinding cracks

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 Heat treatment cracks

07-Sep-17 Slide - 23