2/24/2017

Lecture 1
Introduction to the Failure
of Engineering Materials

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

Failure in Service

Very often, failure occurs to an industrial component during

its service

Failure is inability of a component to assume its intended
function

Major causes of failure include

Improper design, e.g. materials selection, load estimation

Improper processing (fabrication)

Improper use during the service, i.e. abuse of component

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

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 2/24/2017

Example of Failure

Aircraft accident: Aloha flight 243 in 1988

(miraculously only 1 victim)

At 24,000 ft altitude, the upper part of
the fuselage ruptured

Spectacularly, the pilot managed to
land safely the airplane

At that time, the aircraft experienced
89,090 take off-landing cycles, well
beyond designed lifetime (75,000
cycles)

Investigation suggested that the main
cause of failure was fatigue crack
propagation accelerated by corrosion

Lesson learned:

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

Example of Failure

Aircraft accident: Aloha flight 243 in 1988

(miraculously only 1 victim)

At 24,000 ft altitude, the upper part of
the fuselage ruptured

Spectacularly, the pilot managed to
land safely the airplane

At that time, the aircraft experienced
89,090 take off-landing cycles, well
beyond designed lifetime (75,000
cycles)

Investigation suggested that the main
cause of failure was fatigue crack
propagation accelerated by corrosion

Lesson learned:
Do not abuse your components.!!!

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

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 2/24/2017

Example of Failure

The sinking of the unsinkable Titanic, April 1912

(1517 victims)

The hull of the Titanic was made

up of steel having TDBT 30 C

During the voyage to New York,
Titanic collided with an iceberg

The sea temperature was -2C,
way below TDBT

The hull was highly brittle during
the collision

Lesson learned:

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

Example of Failure

The sinking of the unsinkable Titanic, April 1912

(1517 victims)

The hull of the Titanic was made

up of steel having TDBT 30 C

During the voyage to New York,
Titanic collided with an iceberg

The sea temperature was -2C,
way below TDBT

The hull was highly brittle during
the collision

Lesson learned:
Stay above (TDBT).!!!

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

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 2/24/2017

Example of Failure

The collapse of Tacoma Narrows Bridge, 1940

A 1.8 km-long suspension bridge in
Washington state, the first to use plate
girder (I profile beam) to support the
roadbed

The main span collapsed under 64 km/hr
wind 4 months after public opening

Investigation suggested that the main
cause of failure was aeroelastic flutter i.e.
the aerodynamic forces on an object
couple with a structure's natural mode of
vibration to produce rapid periodic
motion
Lesson learned:

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

Example of Failure

The collapse of Tacoma Narrows Bridge, 1940

A 1.8 km-long suspension bridge in
Washington state, the first to use plate
girder (I profile beam) to support the
roadbed

The main span collapsed under 64 km/hr
wind 4 months after public opening

Investigation suggested that the main
cause of failure was aeroelastic flutter i.e.
the aerodynamic forces on an object
couple with a structure's natural mode of
vibration to produce rapid periodic
motion
Lesson learned:
New design produces unexpected result.!!!

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

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 2/24/2017

Types of Failure

Types of failure commonly encountered

Yielding : permanent deformation

Buckling : excessive elastic deformation

Fracture : component separation

Fatigue : failure due to repeated loading

Creep : deformation that accumulates with time

Corrosion : loss of material due to chemical action

Wear : surface removal due to abrasion or contact

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

Design Approach

Strength of Material
Approach
Applied Stress Yield or Tensile Strength

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

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 2/24/2017

Design Approach

Strength of Material
Approach
Applied Stress Yield or Tensile Strength

Applied Stress

Fracture Mechanics
Approach

Flaw Size Fracture Toughness

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana

Why Learning Design Against Failure?

Avoid failures

Provide general guidelines during the design, manufacturing,
maintenance and use of engineering components

Analyze failures

Investigate the possible root causes of failure in an engineering
component during the service

Provide recommendations so that similar failure can be
prevented in the future

KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana