MT4044 L02 Failure Mode

TEKNIK MATERIAL FTMD ITB
0811227714 & arifbasuki@material.itb.ac.id

DR. IR. ARIF BASUKI arifbasuki@material.itb.ac.id 1
0811227714
0811227714 & arifbasuki@material.itb.ac.id 2
INSTANTANEOUS: PROGRESSIVE:
SEKETIKA TERJADI SAAT PERLU WAKTU DARI
LOAD > CAPACITY SAAT MULAINYA DEGRADASI
SAMPAI KONDISI LOAD > CAPACITY
DEGRADATION:
CAPACITY
THINNING/CRACKING
LOAD
Materials
Structures
CAPACITY
Mechanical LOAD
Electrochemical
Thermal FAIL
TIME=0 TIME > 0

FRACTURE MODE IDENTIFICATION
CAPACITY LOAD
FRACTURE OCCURENCE
STRENGTH < STRESS
INSTANTANEOUS:
Failure at the time of load applications without weakening
 DUCTILE OVERLOAD
 BRITTLE OVERLOAD
PROGRESSIVE:
Failure after a period of time where the strength has degraded due
to the formation of cracks, internal defects or wastage
 FATIGUE
 CREEP
 WEAR
 CORROSION

INSTANTANEOUS FAILURE
Failure at the time of load applications without weakening
Kekuatan Tegangan
Material Kerja GAGAL !
PATAH
475 MPa
PERUBAHAN
350 MPa BENTUK
PERMANEN

tegangan kerja
naik
sifat material
tetap

tegangan kerja sifat material

naik tetap

TEGANGAN KERJA TETAP
KENAIKAN TEMPERATUR
sifat material yang berubah!
SAFE untuk Low Temp.

FAIL untuk High Temp.
Tegangan Kerja

thick-lip stress rupture
X
thin-lip stress rupture

VISUAL APPEARANCE
INSTANTANEOUS DUCTILE & BRITTLE FRACTURE

TENSILE-TEST SPECIMEN

CUP & CONE DUCTILE FRACTURE
OF TENSILE-TEST SPECIMEN
STAGES IN THE CUP-AND-
CONE FRACTURE.
a. Initial necking.
b. Small cavity formation.
c. Coalescence of cavities
to form a crack.
d. Crack propagation.
e. Final shear fracture at a
45o angle relative to the
tensile direction.

V-SHAPED ‘‘CHEVRON’’ MARKINGS
CHARACTERISTIC OF BRITTLE FRACTURE

V-SHAPED ‘‘CHEVRON’’ MARKINGS
CHARACTERISTIC OF BRITTLE FRACTURE

VISUAL APPEARANCE
ASTM A490 HIGH-STRENGTH BOLT TENSILE SPECIMENS

VISUAL APPEARANCE
CHARPY IMPACT TEST : DUCTILE TO BRITTLE TRANSITION

VISUAL & SEM EXAMINATION
CHARPY IMPACT TEST : DUCTILE TO BRITTLE TRANSITION

VISUAL & SEM EXAMINATION
SAE 1010 tie rod adjusting A
sleeve for automobile
steering system
A: cold forming cold-rolled sheet 90o
B: cold-drawn seamless tubing
45o

PROGRESSIVE FAILURE
wall thinning because of aqueous and environment corrosion
Based on the evaluations of material mechanical properties, wall thinning and applied
stresses, a failure criteria was developed to assess failure margins against ductile rupture.

PROGRESSIVE FAILURE
Failure after a period of time where the strength has degraded
due to the formation of cracks, internal defects or wastage.
DEGRADATION STARTS
CAPACITY
THINNING/CRACK INITIATION
FRACTURE/FAILURE
 FATIGUE
 CREEP
 WEAR
CORROSION
LOAD
TIME > 0
FATIGUE FRACTURE
VISUAL APPEARANCE SEM MICROGRAPH

FATIGUE CRACK PROPAGATION
FRACTURE SURFACE

FATIGUE LIMIT STRENGTH
ROTATING BENDING TEST

SKEMA PERMUKAAN PATAH LELAH
TENSION, COMPRESSION, TORSION
Schematic diagrams illustrating characteristic patterns of fatigue beach marks,

ratchet marks, and relative extent of fast overload fracture in cylindrical
components subjected to various loading and notch conditions.
TENSION

TENSION
Fatigue failure of a low-alloy steel part. Shear lips around most of the
periphery (as at arrows) as well as chevron marks over most of the fracture
surface aid in identifying the fatigue fracture area at the upper left corner.

TORSION
Schematic illustrations of initiation and early

stages of propagation of fatigue cracks in rods
Characteristic X-pattern on the surface of
subjected to torsion. Fatigue can initiate on
a medium-carbon steel crankshaft tested
planes of maximum shear (longitudinal or
under reversed torsional fatigue. Fatigue
transverse), then propagate under cyclic or
initiated on a transverse plane of
fluctuating tensile stress acting at 45° to the
maximum shear, then propagated on two
circular rod axis. An X-pattern can form under
pair of helical surfaces.
reversed torsional loading.

SKEMA PERMUKAAN PATAH LELAH
UNIDIRECTIONAL, REVERSED & ROTATING BENDING

unidirectional bending fatigue
Bolt fracture surface produced by unidirectional bending fatigue. The

origin site can be located by tracing the centers of curvature of beach
marks back to the thread root at the arrow.

FAILED SHAFT IN ROTATING BENDING FATIGUE
A, C : fatigue crack origin

B : postfracture contact
rotating bending fatigue
Curved beach marks are centered on the surface origin (arrow) of this
shaft that failed in rotating bending fatigue. Beach marks are nearly
semicircular near the origin. As the crack became larger, it grew more
rapidly near the surface where bending stress was highest, resulting in
semielliptical beach marks.

Carbon steel shaft broken in rotating bending fatigue. Fatigue fracture initiated
at numerous sites along a sharp snap ring groove; ratchet marks appear as
shiny spots along the surface. Cracks coalesced into a single fatigue crack
that—due to the bending stress distribution—grew most rapidly near the
surface, resulting in beach marks that curve away from the origin sites toward
the area of final overload fracture at left
Rotating bending fatigue failure of keyed medium-carbon steel shaft. Fatigue

initiated at a corner of the keyway, as marked. Beach marks in that vicinity are
concentric about the origin. As the fatigue crack grew, the bending stress
istribution produced more rapid growth near the shaft surface. Consequently,
beach marks in the later stages of life curved toward the final overload zone.
Roughness of the fracture surface also increased nearer the final overload
zone.
reversed bending fatigue
This broken 30 mm (1.2 in.) diameter steel shaft exhibits flat, relatively
smooth fracture, without shear lips and with generally horizontal beach
marks, at top and bottom areas. Along with ratchet marks (four distinct
ratchet marks are evident along the top edge), these features are consistent
with reversed bending fatigue having multiple origins.
FATIGUE CRACK PROPAGATION RATE

CRACK PROPAGATION RATE
A, m: materials
properties

FATIGUE LIFE PREDICTION

FATIGUE LIFE PREDICTION

BULK
CREEP DAMAGE OF A COBALT-BASE ALLOY

TURBINE VANE FROM OVERHEATING
LOCAL
CREEP CRACK IN A TURBINE VANE

gage
length
constant
stress
Thermo-
couple heating
element
constant
temperature
L0
gage length
REGANGAN, STRAIN
e = DL/L0
DLs
s AKIBAT KENAIKAN TEGANGAN, s

e = s/E
DLT
T AKIBAT KENAIKAN TEMPERATUR, T
e = a DT
AKIBAT GABUNGAN KENAIKAN

TEGANGAN & TEMPERATUR

CONSTANT STRESS & CONSTANT TEMPERATURE
first second third

strain
stage stage stage

rupture
De/Dt : creep rate

regangan
bertambah
De
Dt
regangan
tetap
initial time rupture

strain time
CONSTANT STRESS & CONSTANT LOAD

CONSTANT STRESS & CONSTANT LOAD

CONSTANT STRESS &
CONSTANT TEMPERATURE
T 3 > T 2 > T1
s 3> s 2> s 1
T3 or s3
T2 or s2
T1 or s1

CREEP RATE
Creep rate =
0.1%/1000 h
working stress
operating temperature

strain
De/Dt : creep rate

rupture
DESIGN LIMIT safety

margin
T&s
Life, t
time
Materials
Creep temperature

nickel-base superalloy casting
yield & tensile strength, and creep rupture strength at 1000 and 10,000 h
LARSON-MILLER PARAMETER



CREEP RATE
K, n, Qc : materials properties
R : universal gas constant
Creep rate =
0.1%/1000 h
At
80 MPa; 427oC
35 MPa; 538oC
11 MPa; 649oC

RUPTURE LIFE TIME CREEP
B A STRESS 50 MPA
A Temp. : 538oC
Lifetime : 10000 h
B Temp. : 649oC
Lifetime : 1000 h

DATA EXTRAPOLATION METHODS
Logarithm stress
Larson–Miller Parameter
vs the Larson–
Miller parameter Combine temperature and
for an S-590 iron. rupture time in a constant:
LMP = T(C + log tr)

T : temperature (K)
C : constant (=20)
tr: rupture time (h)

creep deformation and intergranular cracking
in a jet-engine turbine blade

SEM EXAMINATION CREEP
SEM photo at 5000x shows isolated early stage

creep cavitation found in the weld centerline.

LOM EXAMINATION CREEP
early stage creep damage advanced creep microcracking

Decohesion of inclusions and the growth of cavities around the decohered particles.
Eventual linkage of these cavities leads to microcracking and eventual macrocracking

Creep-induced failure of a boiler plate.
a. A polished cross section of the plate that shows necking, a feature
of short-term creep. 2×.
b. Intergranular voids (dark areas) in an area near the fracture
surface

a b c
Stress rupture of heater tube.
(a) Heater tube that failed due to stress rupture.
(b) and (c) Stress-rupture voids near the fracture.
SEM EXAMINATION CREEP
SEM photo at 5000x shows isolated early stage

creep cavitation found in the weld centerline.

LOM EXAMINATION CREEP
early stage creep damage advanced creep microcracking

Decohesion of inclusions and the growth of cavities around the decohered particles.
Eventual linkage of these cavities leads to microcracking and eventual macrocracking

CREEP

CREEP RATE
K, n, Qc : materials properties
R : universal gas constant
Creep rate =
0.1%/1000 h
At
80 MPa; 427oC
35 MPa; 538oC
11 MPa; 649oC

RUPTURE LIFE TIME CREEP
B A STRESS 50 MPA
A Temp. : 538oC
Lifetime : 10000 h
B Temp. : 649oC
Lifetime : 1000 h

DATA EXTRAPOLATION METHODS
Logarithm stress
Larson–Miller Parameter
vs the Larson–
Miller parameter Combine temperature and
for an S-590 iron. rupture time in a constant:
LMP = T(C + log tr)

T : temperature (K)
C : constant (=20)
tr: rupture time (h)


MT4044 L02 Failure Mode

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TEKNIK MATERIAL FTMD ITB

0811227714 & arifbasuki@material.itb.ac.id

TIME=0 TIME > 0

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tegangan kerja sifat material

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TEGANGAN KERJA TETAP

SAFE untuk Low Temp.

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thick-lip stress rupture

INSTANTANEOUS DUCTILE & BRITTLE FRACTURE

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wall thinning because of aqueous and environment corrosion

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VISUAL APPEARANCE SEM MICROGRAPH

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Schematic diagrams illustrating characteristic patterns of fatigue beach marks,

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Schematic illustrations of initiation and early

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Bolt fracture surface produced by unidirectional bending fatigue. The

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A, C : fatigue crack origin

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Rotating bending fatigue failure of keyed medium-carbon steel shaft. Fatigue

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CREEP DAMAGE OF A COBALT-BASE ALLOY

CREEP CRACK IN A TURBINE VANE

s AKIBAT KENAIKAN TEGANGAN, s

T AKIBAT KENAIKAN TEMPERATUR, T

AKIBAT GABUNGAN KENAIKAN

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first second third

stage stage stage

De/Dt : creep rate

initial time rupture

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De/Dt : creep rate

DESIGN LIMIT safety

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