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
1
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
2
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
3
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
5
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
