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andFailureAnalysis
Centerfor MaterialProcessing
Indonesia
Universitas
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TechnicalReport
DocumentNo: L-0161/SNCMPFAnU 5
Crack ldentificationof ERWSteelTube
Preparedfor: PT. lndonesia Steel Tube Wotus(lSfW
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Office addrea:
Lab UjiMetalurgi(LUM)
Departemen
TeknikMetalurgidan lvlaterial
FakultasTeknikUniversitas
lndonesia
K?mpusBaruUl DeDok16424
-78888'1
Telp:021-786351
0, 78849045Fax:02'1
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[Link]:lum@[Link]
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Center fol Materials ProcessinE and Failure Aralysi$
Univrsilas [Link]
Technical Rcfort
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No. : L-016l /SA/CMPFA/2015
GITIPFA
R-gportDocumenlldeEtiligs
DocumentNo"
[Link]
ReportTitle
JudulLaporan
Dateof lssue
Tanggal Selesai
ServiceUser
PemakaiJasa
UserAddress
Alamat PemakaiJasa
Material
Bahan
Materialldentities
ldentitasBahan
TestinqTvpes
Jenis Pengujian
TestinqApparatus
Alat Uji
Testinq Standards
StandardUji
5
L-016'1/SfuCMPFAJ2O,1
of ERWSteelTube
Crackldentification
April21"r,2015
Works(ISTW;
[Link]
SteelTube
PuloGadung
Fe-Based
SteelTube
Metallographic
(EDS)
X-RaySpectroscopy
EnergyDispersive
sEtvl
EDSEDAXAppolloX
ASTME3
ASTME4O7
Repod lssuance
S.T
BintangSuryoHeidiansyah,
or waffanties,either exprcssedor implied,
Meta urgy and Mateial Depaftmentnakes no representations
ptovicles
"as
is' basedon the infoffiation provjdedby client.
the rcsultsof this repoft
and specificatly
Phone:021-7863510,78849045
Fax 021-76EE8'111E-mail:lul(iloClaluilg jd
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Ccnterfor MaterialsPrucssinlland FailureAnalysis
Univensitashdonesia
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TechnicalReport
No. : L-0 16I /SA,/CWFA,/201
5
SIP-EA
l. Background
PT. ISTW requestedlab analysisfor their productseen in figure '[Link] clientinformed
that the crackis foundon the surfaceof the [Link] analysisis performedto identify
the possiblecauseof crackwhichoccurredin the weldseamafterthe exoansionDrocess.
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Figure l. As ReceivedSample
ll. Scopeof Testing
The analysisis caniedout at CMPFAlab, Universitas
[Link] scopeof testingis as
follows:
.
MicrostructureObservationby Light Microscope
Chemicalcomposition
by EDS
lll. TestingResultand Discussion
lll.l Microstructure
Testby SEM
Microstructure
testingis performed
to observethe microstructure
of the tubeusingSEM.
Observation
is doneto the thleesamDles
as illustrated
in TableL SamDle1 is takenat
thecrosssectionof the crack,sample2 is takenat the surfaceof thecrackandsample3
is takenat the undeformed
lield [Link]
of thetestresultsby usingSEM
areasfollows(seeTablel).
jd
Phone:021-7863510,78849045
Fa* 021-7888811'lE-mail:
Page3ofT
lum@[Link].
Centerfor ilaterials Prucesdngand Failurc /lnalysls
Urdve|.sihslndonosia
TeohnioalReport
As receivedSample
No. : L0 161/S-4/CWFA./2015
Tablel. Microstructure
TestResultby usingSEM
TestedSample
Observation
Microstructure
Microstruc{ure
of SamDleI
Microstruc{uF
oi SamDle2
Microstructure
of SamDle
3
t
Phone:021-7863510,
78849M5 Fax 02'1-78888'111
E-mail:lll!]@EqblUEqu
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Centerfor MatsrialsPrucssingard F&ilureAnalysis
Univorsitashdolesia
TechnicalRcport
No. : L-016lEACWFU29I5
lll.2 ChemicalCompositionby EDS
EnergyDispersive
(EDS)is performed
phase(inclusions)
Spectroscopy
on the suspicious
foundnearbythe [Link] locationtestareaandtest resultsfor EDSare presented
in
table2.
Table2. Elements
foundintheinclusions
afterEDStest.
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Phone:021-7863510,78849045
Fax 021-78888111E-mait:IUI@[Link]
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Cnterfor MaterialsProcessingand Faihre Analysis
UnivrsitasIndonesia
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TechnicalReport
lV. Discussion
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l-D.
In the ERW process,strip is fed into a formingmill, shapedinto a cylinderand passed
through an inductioncoil or under contacts (figure '1a). The magneticfield around
inductioncoil causescurrentto flow on the edgesof the [Link] edges,in turn,heat up
due to resistanceto the flow of [Link] hot edgesare forgedtogetherin the weld rolls
and a weld is [Link] weld is a true forgeweld in that no fillermetalis addedand, if
doneproperly,no moltenor oxidizedmetalis left on the [Link] 1b showsthat
all of the liquidusand metal oxides are squeezedout of the weld as the edges pass
betvveen
the weld rolls.
No.: L-0161/SA./CWFA/2015
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It is found that the possibleoccurrenceof certainkindsof weld defectsis determinedby
duringwelding:A possiblewelddefectis a coldweld
the typesof phenomenaencountered
and a [Link] cold weld is composedof a colonyof oxideswhichare formedon
the edge surfacesand remainbecausethey are not squeezedout from betweenthem.
The penetratorby natureis a slag inclusionproducedwhen moltenslag is drawn into a
gappedzoneby the actionof surfacetensionand capillaryeffectsin a returningprocessof
the moltenbead.
A cold weld occursuniformlyover a wide rangealongthe weld line, and any accidental
ohenomenaare not consideredto accountfor the cold weld.A numberof extrusionsare
point.
to the V-convergency
observedto be formedon boththe edgesurfacesapproaching
These extrusionswere sandwichedbetweenthe edges when they were welded. lt is
consideredthat the extrusionsconsistmostlyof [Link] reasonfor this is that it should
pressureif the
not be possibleto form such extrusionsagainststrongelectromagnetic
extrusionsconsistof [Link],the cold weld is a colonyof oxidesformedon the edge
surfacesthat remainbecausethey were not squeezedout from betweenthem; this has
beenconceivedto be a mechanismof producingall welddefectsin ERW.
SEM observationresullat the sample1 and sample2 showsthat inclusionswere found
nearbythe crack (table 1). The inclusionwas then checkedusing EDS, the test result
Phone:021-7863510,78849045
Fax:021-78888111
E-mail:um@[Link]
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Centerfor aterials ProcessinEand FailuroAnalysis
Univensitas
lndonesia
TeohnicalReport
No. : L-016l /SACMPFA/2o
I5
CIUPFA
showsdominantelementof Carbon,Oxygen,Manganese
and [Link] come
from dirt or [Link] and Manganesetogetherwith Oxygenmay form Oxides.
The metaloxidemay havebeentrappedon the bondplaneinsteadof beingsqueezedout
with the [Link] formedon the surfaceof lhe moltenmetaledges
in the vee. In the vee, if the approachvelocityof the stripedgesis less that the melt rate,
i.e.,the edgesare meltingfasterthantheyare beingsqueezed,a pocketforms(figure 3a)
behindthe vee apexwill containbothmoltenmetaland [Link] normalsqueeze
out does not completelyremovethe largerthan normalliquidvolumeand an entrapment
results(figure 3b).
Pockelbehindapex
B
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Oxides
and
L'quid
Centerline
of
weldrolls.
(Penetrators)
Entrapments
Figure3, Schemaljc
Oxjdes
V. Conclusion
Visually,crackis foundat one areaof the [Link] crackis foundon otherarea.
After cutting,the crackis analysedwith SEM and inclusionsare foundaroundthe crack.
These inclusionsare not found at the good weld line on other area. The inclusionis
composedof manganeseand oxygenin dominantquantity,lt ls confimed that the crack
was found after expansionand was caused by lhe presenceof manganeseoxides
inclusion
in theweldline.
Phone:021-7863510,7A8/9045Fax 021-7888811
1 E-mail:lurn@meta.!aci.l
paeeTotj
