JULY 2020 CONFIDENTIAL

MARKS:

= /50
= / 100
UNIVERSITI KUALA LUMPUR
MALAYSIAN FRANCE INSTITUTE

FINAL ASSESSMENT 3 (TEST 5)

JULY 2020 SEMESTER

COURSE CODE : FTB 43203 / FTB 36403

COURSE NAME : FAILURE ANALYSIS

PROGRAMME NAME : BET WQI

DATE / TIME :

DURATION : 1 HOUR

NAME / ID NUMBER :

INSTRUCTIONS TO CANDIDATES
1. Please CAREFULLY read the instructions given in the question paper.
2. This question paper is for Online Test only.
3. You need to record a video during the Online Test and share the video in the
Microsoft Teams. Video can be recorded via handphone or directly via Microsoft
Teams. The video must be uploaded together with the completed Test Paper in
Microsoft Teams BEFORE 5pm.
4. You have been given duration from 8.30 am until 5pm to complete the Online Test.
5. The uploaded video and test paper which submitted AFTER 5pm will be consider
ABSENT.
6. Answer ALL questions in the space and column given. The answer must be typed
and for question that needs to draw, you can either use digital or manual
sketching.
7. If you choose to draw manually, the answer should be scan and paste in the
column given and submit online via Microsoft Teams Only.

THERE ARE 5 PAGES OF QUESTIONS, INCLUDING THIS PAGE.

JULY 2020 CONFIDENTIAL

Answer ALL questions (50 marks)

1. Microscopic observation of a fatigue fracture reveals the propagation mechanism.

Indication of fatigue striations mostly found in ductile materials, such as the ones used for
machine construction. Describe the stage involved in fatigue fracture based on the
macroscopic progression marks in Fig. 1 below.
(_______/15 marks, C4)

Fig. 1 Macroscopic Image

Answer (at least 250 words):

Fatigue fracture is the buildup and crack propagation because of repeated or cyclical
loading, and it may come from tensile, compressive or torsional load. As seen in the
figure above, the diagram illustrates the crack growth of the material after it has failed
completely into two separate parts. This crack growth can be defined into three stages of
fatigue fracture:
I. Stage 1 (Initiation)
II. Stage 2 (Propagation)
III. Stage 3 (Final Rupture)

The most important factor in the Stage 1 (Initiation) of fatigue fracture is that irreversible
changes in the metal are caused by repeated shear stress. Fatigue fracture almost
always initiate at a free surface and near a stress riser for example, the toe of a weld. The
initial development of the fatigue fracture occurs at localised discontinuities in the crystal
structure of the metal. In reality, the generation and movement of discontinuities

FTB 43203 / FTB 36403 FAILURE ANALYSIS Page 2 of 5

Document No : UniKL MFI_SD_AC41(a)
Revision No: 03
Effective Date: 01 March 2016
JULY 2020 CONFIDENTIAL

strengthens the metal by plastic deformation. This phenomenon is called work hardening.
As the metal are work hardens, it loses the ability to deform plastically in a localised
region where cyclic stress is visible. And once the metal meets its plastic deformation
limit, the discontinuity becomes a small crack.

When cracking is initiated, Stage 2 (Propagation) is start when the continuous cyclical
stress repeats the process, slowly increasing the micro-crack, which becomes a threat to
the structural integrity. Usually, on the Stage 2, the marks features showing the
macroscopic progress marks on the surface of the fatigue fracture, which indicate the
successive locations of the progressive crack front. The propagation stage of fatigue
fracture causes the microcrack to change direction and to expand perpendicular to tensile
stress. The second or propagation stage of fatigue fracture is typically the most easily
detected region of fatigue fracture.

The Stage 3 (Final Rupture) is the final rupture of the component, which happens in the
last load cycle. This final rupture occurs when the crack meets the critical crack size for
unstable propagation. The final fracture area corresponds to the applied mean stress,
which means that greater loads normally lead to a greater final fracture area. Sensitivity of
the material to crack propagation also plays a role; materials that are more sensitive show
a larger final fracture area. By observing under the Optical Microscope (OM), it may
describe the characteristics of the fracture surface, either a ductile fracture or a brittle
fracture, depending on the material, thickness, temperature and stress applied.

2. Atomic force microscope (AFM) is a type of scanning probe microscopy which designed
to measure local properties, such as height and friction with a probe. Briefly explain the
working principle of AFM as designated in Fig. 2.
(_______/20 marks, C5)

FTB 43203 / FTB 36403 FAILURE ANALYSIS Page 3 of 5

Document No : UniKL MFI_SD_AC41(a)
Revision No: 03
Effective Date: 01 March 2016
JULY 2020 CONFIDENTIAL

Fig. 2 Schematic diagram of AFM’s working principle

Answer (at least 300 words):

An Atomic Force Microscope (AFM) uses a cantilever with a very sharp tip on a
micromachined silicon probe to scan a sample surface. When the tip reaches the surface,
the close-range, enticing force between the surface and the tip causes the cantilever to
deflect towards the surface. This tip is used by raster scanning across the surface line by
line to image a sample, although the technique differs drastically between different
operating modes. However, when the cantilever is brought even closer to the surface, so
that the tip comes into contact with it is gradually repulsive and causes the cantilever to
deflect away from the surface. The data on the topography of the sample is also given by
these forces. As touch mode and dynamic, or tapping mode, the two primary classes of
operating modes are commonly defined.

A laser beam is used to detect cantilever deflections towards or away from the surface.
By reflecting an incident beam off the flat top of the cantilever, any cantilever deflection
will cause slight changes in the direction of the reflected an incident beam off the flat top
of the cantilever. A position-sensitive photo diode (PSPD) can be used to track these
changes. Thus, if an AFM tip passes over a raised surface feature, the resulting cantilever
deflection (and the subsequent change in direction of reflected beam) is recorded by the
PSPD.

An AFM images the topography of a sample surface by scanning the cantilever over a

FTB 43203 / FTB 36403 FAILURE ANALYSIS Page 4 of 5

Document No : UniKL MFI_SD_AC41(a)
Revision No: 03
Effective Date: 01 March 2016
JULY 2020 CONFIDENTIAL

region of interest. An AFM takes the image of the sample's surface topography by force.
The raised and lowered features on the sample surface influence the deflection of the
cantilever, which is monitored by the PSPD. By using a feedback loop to control the
height of the tip above the surface—thus maintaining constant laser position—the AFM
can generate an accurate topographic map of the surface features.

3. Manufacturing processes are the most common causes of residual stress and most of all
manufacturing and fabricating processes such as casting, welding, machining, and
forging introduce residual stresses into the manufactured object. Discuss the importance
of residual stresses and how it affects the material’s performance.
(_________/15 marks, C5)
Answer (at least 250 words):
Residual stresses are those which remain in the object (in particular the welded
component) is stressed beyond its elastic limit, resulting in plastic deformation, residual
stresses are produced even in the absence of external loading or thermal gradients. In
certain cases, residual stress results in a severe plastic deformation leading to warping
and distortion of the material. Others have an effect on the vulnerability to fracture and
fatigue. Residual stress can be tensile or compressive. In addition, tensile and
compressive residual stresses may co-exist within a component. Depending on if the
pressure is tensile or compressive, residual stresses may be beneficial or detrimental.
Surface residual compressive stresses are also usually desirable since they reduce the
impact of tensile stresses applied. In certain cases, residual stresses are implemented in
the designs of certain applications for positive effects. This can be done by laser peening,
which imparts compressive residual stresses to an object's surface, allowing thin pieces
to be reinforced or brittle surfaces to be toughened.

In certain cases, the welded joints are wide, have reduced material properties for example
stress corrosion resistance cracking, fracture strength and contain defects. Welded joints
prove to be critical positions in terms of construction and maintenance. Residual stress in
welding is also a primary concern. Residual stress in welding is primarily the result of
thermal expansion, which means that materials expand or contract with temperature.
Typical engineering materials tend to shrink in size as they cool down. As we all know,
welding is a highly thermal process where considerable heat is applied to the welding
joint. The material within the welding joint shrinks as it cools and as a result, the residual
welding tension develops as the nearby material pulls back to establish a bond with the
shrinking welding material.

FTB 43203 / FTB 36403 FAILURE ANALYSIS Page 5 of 5

Document No : UniKL MFI_SD_AC41(a)
Revision No: 03
Effective Date: 01 March 2016