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Cas e S t u d y: Er o s i o n
INTRODUCTION REFERENCES
Cavitation erosion
2 All the literature study to
support this presentation
Injection molding
3
INTRODUCTION
Cavitation
The abrupt variation of the cross section in the fluid system causes the
sudden changes in fluid pressure
INTRODUCTION
Injection Moulding: Nozzle
• The function of the nozzle is to handle both coolant and compressed air,
Gambar
which are separated by an O-ring inside the nozzle pendukung
• The nozzle assembly is composed of the dissimilar metal components-
stainless steel and aluminium alloy (Fig 2)
Gambar
• When the coolant is pumped into the nozzle chamber, the coolant pressure
pendukung
would drop due to the sudden increase in space (Fig. 3). When the coolant
reaches the tube, the pressure would increase as the space decreases
Indikasi kegagalan (figure kaca pembesar sherlock
holmes)
• Nozzle has been in use since 2005 to 2011: A rusty/muddy appearance in the coolant
• Guided by the consultant’s recommendation, the plant applied a corrosion inhibitor
named Maxiguard into the coolant to counteract the appearance of the rusty/muddy
colour.
• The cooling system was flushed with a chemical named Drewclean 26 prior to dosing
the Maxiguard. After the Maxiguard was added, the production crews started noticing
bubbles appearing in the sight glass of the flow meter. Further investigation found that
the aluminium alloy components in the nozzle units had failed. The maintenance
records show that the aluminium alloy components failed in only a few months of
service. Hence, the failure of the aluminium alloy components was a deemed
premature failure.
Indikasi kegagalan (figure kaca pembesar sherlock
holmes)
• As no nozzle failure occurred before the flushing and the chemical dosing, the
client believed that the aluminium alloy component failure was due to chemical
corrosion caused by either Drewclean 26 or Maxiguard in the coolant. The client
requested the author to resolve the corrosion problem.
• The author conducted a site investigation in the plant. Visual inspections found
that on the failed region of the aluminium alloy components appeared smooth
pits (Fig. 3). The pitting location was limited to the tube tip region, not in the
entire tube inner surface. As the bubble’s appearance was associated with the
nozzle failure, therefore, it was almost certain that cavitation erosion was
involved in the failure. However, other corrosions could also combine with the
cavitation erosion in the failures.
REVIEW