Shaiful Rizam Shamsudin

FAILURE ANALYSIS OF CRANE WIRE ROPE

A failure analysis of a broken multi strand wire rope from an offshore platform crane was performed. The wire rope was operated for less than 5 years. The wire consists of seven strands, one central strand and six strands around it. The diameter of the small wires was about 0.78-0.94 mm and the larger wires was a round of 1.52 - 1.78 mm. The large size wires were found fractured by cyclic torsional stresses as characterized by the presence of fatigue cracking originating from the outer surface of the wire. Meanwhile the smaller wires were fractured in a ductile manner under excessive load after the larger wire broken out due to the fatigue mechanism.

A study on hardness behavior of geopolymer paste in different condition

This study has been conducted to understand the hardness behavior of geopolymer paste in different conditions; with and without being immersed in water. Geopolymer paste has been used nowadays as an alternative way to reduce global warming pollution by carbon dioxide (CO2) released to the air caused from the production of Ordinary Portland Cement (OPC). Geopolymer has many advantages such as high compressive strength, lower water absorption and lower porosity. Geopolymer paste in this study was made from a mixture of fly ash and alkaline activators. The alkaline activators that have been used were sodium hydroxide (NaOH) solution and sodium silicate (Na2SiO3) solution. Then the mixture was allowed to harden for 24hrs at ambient temperature and then placed in the oven for 24hrs with 60°C for the curing process. The hardness testing was conducted after a few months when the samples already achieved the optimum design. The samples were divided to two conditions; without immersion which was placed at ambient ...

The Root Caused Analysis of Leakaged Heat Exchanger Tube

Abstract AISI type 316L stainless steel was used as a heat exchanger tube material in an inter-cooler column. After less than a year of operation, severe corrosion failures occurred and a transverse opening leakage was observed on one of the heat exchanger tubes. The failed tube was carefully analyzed using various metallurgical laboratory equipments. The root cause of the tube leakage was believed due to the presence of horizontal micro and macro pores as a hydrogen gas entrapment during casting of the parent ingot. The overlapped and gaping pores formed notch on the shell side of the tube surface, and it increasingly evident when the use of a high-energy water-jet and metal brush as cleaning procedure results in an establishment of pitting type local-action corrosion cells penetrated the tube wall. As a result, corrosive fluid in the tube side dissolved into the cooling water, accelerating the corrosion process.

Failure investigation on rusty mesh strainer of petrochemical plant

The wire material of filter mesh is made of 304 grade stainless steel. The failure to run properly was due to the impact of burst and torn. The client also expects that the failure was due to corrosion problems. A visual inspection on the strainer mesh was found covered by brownish rust layers and some scratches at the damaged area. The rusty wire mesh that was washed with pickling acid showed a clean and smooth surface. Energy dispersive spectroscopy (EDS) examination of the rusty wire mesh surface indicated that it was only normal oxide precipitates. Thus, its proven that there were no signs of severe corrosion attack on the failed sample. SEM micrographs showed the unidirectional scratch effects exist in the damaged area. The fractography study was found there was a typical ductile structure on the fracture surface of the wire. It is proven that the wire mesh was actually still in good condition and has not experienced any embrittlement problems as if it exposed to any corrosive environment. The root cause of the failure is shown by the effect of scratches in which it is usually caused by a mechanical forceful push by a hard object or in other words, it is caused by human error factor.

An Electrochemical Impedance Spectroscopy Study of Al-Zn and Al-Zn-Sn Alloys in Tropical Seawater

In this paper, a study on the electrochemical behaviour and electrical properties of Al-Zn and Al-Zn-Sn alloys in tropical seawater using open circuit potential (OCP) measurement and electrochemical impedance spectroscopy (EIS) are reported. The results from both the OCP and EIS tests show that surface activation was observed in the Al-Zn alloy with the addition of 1.34 wt.% Sn which can be manifested by the shift of OCP values towards more electronegative direction. The EIS spectra of Al-Zn alloy exhibits a semicircle loop, while the EIS spectra for the Al-Zn-Sn alloy exhibits a semicircle with a semicircle inductive loop. The change in EIS spectra for Al-Zn-Sn alloy is correlated to the increase of surface activation resulting in a less stable passive layer. Equivalent circuits models were proposed to fit the impedance spectra and the corresponding electrical parameters with optimum values were deduced. The modulus impedance in the low frequency region or polarization resistance, Rpol obtained for the Al-Zn-Sn alloy, Rpol = 2.76 kΩ cm2) is slightly decreased compared to the corresponding value of the Al-Zn alloy, Rpol = 3.97 kΩ cm2), indicating a considerable reduction in the protective capability of the oxide layer on the Al-Zn-Sn alloy. It appears that the heterogeneous oxide film and pores formed on the Al-Zn-Sn alloy play a key role in reducing total resistance to the flow of electron at the alloy-electrolyte interface.

Corrosion study on high power feeding of telecomunication copper cable in 5 wt.% CaSO4.2H2O solution

The studies were carried out to find out the best powering scheme over the copper telephone line. It was expected that the application of the higher power feeding could increase the data transfer and capable of providing the customer’s satisfaction. To realize the application of higher remote power feeding, the potential of corrosion problem on Cu cables was studied. The natural corrosion behaviour of copper cable in the 0.5% CaSO4.2H2O solution was studied in term of open circuit potential for 30 days. The corrosion behaviour of higher power feeding was studied by the immersion and the planned interval test to determine the corrosion rate as well as the effect of voltage magnitudes and the current scheme i.e. positive direct (DC+) and alternating current (AC) at about 0.40 ± 0.01 mA/ cm2 current density. In the immersion test, both DC+ and AC scheme showed the increasing of feeding voltage magnitude has increased the corrosion rate of Cu samples starting from 60 to 100 volts. It was then reduced at about...

The Effects of Rolling Deformation and Annealing Treatment on Damping Capacity of 1200 Aluminium Alloy

Annealing treatment is an important step of rolling deformation that contributes to microstructural evolution and leads to the significant changes in damping capacity. Damping capacities were analyzed in the parallel to rolling direction at 1 and 10 Hz respectively. It was found that severe plastic deformation at 40 percent reduction has lower damping capacity compared to that of 30 percent and 20 percent reductions respectively. The microstructural results show that the grains of as rolled alloys were changed to almost equiaxed structures after a rolling reduction at 40 percent reduction.

Superhydrophobicity of Textured Ceramic Coating for Corrosion Protection in Marine Applications – A Brief Review

Technology for surface protection in contact with seawater has been studied. It mainly focuses on the capability of superhydrophobicity characteristic. Currently, the application of superhydrophobicity in controlling corrosion problem in the marine environment is still new. The development of superhydrophobicity on the materials surface can be achieved by designing a specific texture pattern in micro-or nanometer scale for producing high roughness surface. This review paper is mainly on the laser technology for producing superhydrophobicity characteristic of materials surface. This technique offers the most control and precision over the produced geometry.

Electrochemical corrosion behaviour of Mg-(Ca,Mn) sacrificial anodes

The aim of the study is to identify the effect of Ca in Mg-Mn alloy on electrochemical corrosion behavior for the development of high performance sacrificial anode. Mg alloys were fabricated by casting technique under an inert atmosphere. 0.35 ~ 1.11 wt.% of Ca were added as alloying element. The finding shows that the addition of small Ca in Mg-Mn anodes was found not significantly affecting the corrosion rate. However, small content of Ca was as much as necessary improving electronegativity of open circuit potential and modifying anodic polarization in promoting the instabilities of surface passive layer hence results in the further dissolution process between ion and alloy species underneath. No passivation occurs on the standard samples. Pitting profile only occur on Mg-Mn anode that has lower Ca content (0.35 wt. %). An XRD result shows no present of Mg2Ca phase on the as-cast anode containing 1.11 wt. % Ca. As a conclusion, the influence of small content of Ca was profoundly modifying electrochemically behaviour of Mg containing Mn anodes except corrosion rate.

Joining of Dissimilar 6063 Aluminium Alloy-316L Stainless Steel by Spot Welding: Tensile Shear Strength and Heat Treatment

Tensile shear strength and ageing treatment of dissimilar 6063 aluminum alloy-316L stainless steel joint fabricated by spot welding were investigated. The results showed that tensile shear strength increased with the increasing of welding current. The enhancement of tensile shear strength of the joints was due to the enlargement of the nugget diameter. It was also found that the tensile shear strength values for heat treated joint almost similar to that of non-heat treated joint.