F ai l u r e An al ys i s
Cas e S t u d y: Er o s i o n
The microscopic features of cavitation erosion and the solution
in the plastic injection moulding machines
M e e t T h e Te a m
REVIEW
Background
Result and Discussion
1 3
INTRODUCTION REFERENCES
Cavitation erosion
2 All the literature study to
support this presentation
Injection molding
3
INTRODUCTION
Cavitation
• Cavitation problems occur prevalently in pumps, hydraulic systems,
valves, turbine bearings, etc
• A kind of surface failure by the shock waves or microprojects due to the
vapour bubble collapse (implosion) in the fluids. The bubble implosion
generates broadband high frequency vibration. The vibration intensities
and the frequency ranges vary from case to case, from very weak
vibration to strong vibration
• Identify cavitation issues by vibration analysis
• In failure analysis, cavitation erosion would sometimes be misinterpreted
as flow-accelerated corrosion (FAC) because both the microscopic
features have not been well-established
INTRODUCTION
Cavitation Erosion Flow-Accelerated Corrosion (FAC)
• A mechanical process of material • A corrosion process in which the
removal through bubble implosion. protective oxide film is dissolved
• Often combined with corrosions in by the fluid flow.
industry. • Irrelevant to bubble implosion.
• Pure cavitation erosion is • FAC may be combined with
particularly rare in the real world. cavitation erosion.
• “hammer like’’ blow by the bubble • FAC generates the horseshoe pits or
implosion scalloped appearance
Gambar Gambar Gambar Gambar
pendukung pendukung pendukung pendukung
INTRODUCTION
The microscopic features of
cavitation erosion
Their features vary with the material’s hardness
a) For softer materials, plastic deformation usually occurs with bubble implosion.
b) For harder materials, cavitation leads to fatigue cracks
c) Cavitation erosion on aluminium impeller formed smooth pits
d) Cavitation erosion on diesel engine injector nozzle formed rough pits
e) Cavitation erosion on cylinder liner became deeply pitted and appeared to be spongy
f) Cavitation erosion on booster pump produced plastic deformation and microcracks
which resulted in the large rough pits
g) Stainless steels, copper alloy, and titanium alloy to Al2O3. The features varied from
rough surface craters to smooth scalloped appearance.
h) Stainless steel and carbon steel. The features varied from smooth shallow pits to
rough deep craters
INTRODUCTION
The microscopic features of
cavitation erosion
The cavitation process contains two aspects:
Gambar
a) The vapor bubble formation pendukung
due to the sudden reduction in fluid pressure
a) The bubble collapse Gambar
pendukung
due to the fluid pressure increases in the downstream
The abrupt variation of the cross section in the fluid system causes the
sudden changes in fluid pressure
INTRODUCTION
Injection Moulding: Nozzle
• The function of the nozzle is to handle both coolant and compressed air,
Gambar
which are separated by an O-ring inside the nozzle pendukung
• The nozzle assembly is composed of the dissimilar metal components-
stainless steel and aluminium alloy (Fig 2)
Gambar
• When the coolant is pumped into the nozzle chamber, the coolant pressure
pendukung
would drop due to the sudden increase in space (Fig. 3). When the coolant
reaches the tube, the pressure would increase as the space decreases
Indikasi kegagalan (figure kaca pembesar sherlock
holmes)
• Nozzle has been in use since 2005 to 2011: A rusty/muddy appearance in the coolant
• Guided by the consultant’s recommendation, the plant applied a corrosion inhibitor
named Maxiguard into the coolant to counteract the appearance of the rusty/muddy
colour.
• The cooling system was flushed with a chemical named Drewclean 26 prior to dosing
the Maxiguard. After the Maxiguard was added, the production crews started noticing
bubbles appearing in the sight glass of the flow meter. Further investigation found that
the aluminium alloy components in the nozzle units had failed. The maintenance
records show that the aluminium alloy components failed in only a few months of
service. Hence, the failure of the aluminium alloy components was a deemed
premature failure.
Indikasi kegagalan (figure kaca pembesar sherlock
holmes)
• As no nozzle failure occurred before the flushing and the chemical dosing, the
client believed that the aluminium alloy component failure was due to chemical
corrosion caused by either Drewclean 26 or Maxiguard in the coolant. The client
requested the author to resolve the corrosion problem.
• The author conducted a site investigation in the plant. Visual inspections found
that on the failed region of the aluminium alloy components appeared smooth
pits (Fig. 3). The pitting location was limited to the tube tip region, not in the
entire tube inner surface. As the bubble’s appearance was associated with the
nozzle failure, therefore, it was almost certain that cavitation erosion was
involved in the failure. However, other corrosions could also combine with the
cavitation erosion in the failures.
REVIEW
• Uji korosi dengan galvanic test
REFERENCES
• Liu, W. 2014. The microscopic features of cavitation erosion and the
solution in the plastic injection moulding machines. Engineering
Failure Analysis. Elsevier. Vol 36. page 253 – 261.
