engineering material assignment

7/21/2019 engineering material assignment

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NEAR EAST UNIVERSITY

Faculty of Engineering

Department of Petroleum and Ga Engineering

Pro!ect " #aterial

#E "$$

Student% #u&ammad Umair 'a&id( ")$*++,,



Structural and component failure

T&e Titanic i a famou e-ample of a material.related caue of failure/ 0n &er

maiden 1oyage2 Titanic truc3 an ice4erg on t&e nig&t of April $,t& $5$" and an3a fe6 &our later on t&e morning of April $+t&/ T&ere are limitle reaon t&at can

4e argued to &a1e caued t&i tragic in3ing 4ut t&e material Titanic 6a

contructed from can are t&e only real reaon t&at can 4e pro1en/ T&roug& careful

analyi of &o6 &e 6a engineered and deigned2 it i clear Titanic 6a doomed

from t&e tart/

T&e main reaon t&e &ull teel2 and t&e ri1et t&at &eld t&e teel plate toget&er2

failed 6a t&e reult of 4rittle fracture/ 7rittle fracture occur in tructural material

t&at are caued 4y lo6 temperature2 &ig& impact loading2 and &ig& ulfur content/

8oincidently2 6&en t&e Titanic truc3 t&e ice4erg2 all t&ree factor 6ere preent/

T&e temperature of t&e 6ater 6a 4elo6 free9ing2 t&e &ip 6a cruiing &ig&

peed and t&e &ull teel &ad &ig& le1el of ulfur/

All t&ree million of Titanic: ri1et 6ere dri1en 4y &and/ ; <roug&t iron i an Iron

Alloy 6it& a 1ery lo6 car4on =)/$ to )/"+>? content in contrat to cat iron ="/$>

to ,>?2 and &a fi4rou incluion2 3no6n a lag up to "> 4y 6eig&t/

It 6a t&ee faulty material t&at lead to t&i tragedy if t&ee ame material 6ere

replaced 4y ome mentioned 4elo6 t&i 3ind of incident can 4e pre1ented/

@ere i a lit and a 4rief introduction of t&e material and met&od can re4uild t&e

titanic 4etter and afer/



Engineering #aterial

In t&e &ip4uilding indutry and eentially in engineering2 copper alloy are 1ery

common/ It i conditioned 4y t&eir &ig& corroion reitance2 adeuate trengt&under 1ariou load2 &ig& antifriction propertie2 &eat and electro conducti1ity a

6ell a reitance to fouling/ 8opper2 copper.nic3el alloy2 aluminum2 tin and

ilicon 4ron9e and 4ra are ued for manufacture of ource 6ater pipeline2 &ip

fitting2 pump2 propeller2 &eat e-c&anger2 &aft liner2 etc/

Aluminum alloy are ued a cat in manufacture of 1ariou critical part and2

particularly2 piton and caing for internal com4ution engine/

Steel i a tructural teel 6it& a pecified minimum yield trengt& of *++ NBmmC/

S&ip4uilding teel i t&e mot common material/ It i to meet rat&er trict

reuirement% trengt&2 fle-i4ility2 &ig& manufactura4ility2 6eld a4ility2 cot2

repara4ility2 etc/ Steel ued in t&e dometic &ip4uilding indutry differ in &ig&

cold.reitance2 good 6elding c&aracteritic and increaed fracture trengt&/

Special cold.reitant 6elding conuma4le 6ere 6or3ed up for ne6 teel grade/

at year2 ne6 cla of &ig&.trengt& corroion.reitant nitrogen.alloyed teel

grade 6ere ela4orated/ 06ing to difference in interaction of atom of car4on and

nitrogen 6it& atom of iron2 teel acuire uniue p&yicoc&emical and operating

propertie =&ig& trengt&2 fle-i4ility2 a4olute corroion reitance2 non.magnetic 4e&a1ior?/ Nitrogen teel differ in good 6elding c&aracteritic and

manufactura4ility2 4ot& in metallurgical production and &ip4uilding/

Structural aluminum alloy 6it& increaed corroion reitance a 6ell a

aluminum.4aed compoite material 4ecame common ue in contruction of &ig&.

peed ea and ri1er 1eel2 a 6ell a airfoil 4oat2 &ydrofoil &ip and aerotatic

craft/

06ing to t&eir propertie2 titanium alloy 4ecame common ue in marine facilitie/

Ditincti1e c&aracteritic of t&eir uage i 6ide pectrum of operationalen1ironment 6it& long er1ice life/ In addition to it2 t&e di1erity of type of &alf.

fini&ed item ued in &ip tructure manufacture i 1ery important/

'inc i rat&er corroion.reitant material 4ot& in air and in 6ater/ Rolled 9inc i

ued in in4oard plan3ing of &ip room/ Alo2 t&ic3 plate of rolled 9inc are ued in



manufacture of protector/ 'inc coating 4ecome common ue in corroion

pre1ention for metal urface of &ip ytem/

En1ironmental afety of ne6 &ip i enured 6it& uage of non.metallic material

6it& lo6 emiion of c&emical compound into 6ater and air/ So2 1ariou 3ind of

fi4ergla platic are ued in contruction of &ull of ome 1eel =tra6ler2

6eeper2 &ig&.peed airfoil and &ydrofoil &ip2 and yac&t?/ T&e main property of

t&e fi4ergla platic i t&eir c&emical and 4iological ta4ility/ Strengt& and

tec&nological propertie2 impro1ement of 6or3ing condition2 and reduction of

cot of 6or3room air 1entilation are t&eir ad1antage/

Ne6 polymeric and metal.polymeric compoition material gi1e poi4ility to

produce non.compoite or partly rigid &ull tructure of and6ic&.contruction

6it& &ig&.tenile teel or fi4ergla outide layer and polymeric or lo6.tenile

compoite interlayer/ Suc& &ull 4ecome common ue in 4uilding of modern &ig&.peed 1eel/

T&e tructural frame6or3 of mot &ip i contructed of 1ariou grade of mild

and &ig&.trengt& teel/ Steel pro1ide t&e forma4ility2 mac&ina4ility and 6eld

a4ility reuired2 com4ined 6it& t&e trengt& needed for ocean.going 1eel/

Variou grade of teel predominate in t&e contruction of mot &ip2 alt&oug&

aluminum and ot&er nonferrou material are ued for ome upertructure =e/g/2

dec3.&oue? and ot&er pecific area 6it&in t&e &ip/ 0t&er material found on

&ip2 li3e tainle teel2 gal1ani9ed teel and copper.nic3el alloy2 are ued for a

1ariety of corroion.reitance purpoe and to impro1e tructural integrity/

@o6e1er2 nonferrou material are ued in far le uantity t&an teel/ S&ip4oard

ytem =e/g/2 1entilation2 com4at2 na1igational and piping? are uually 6&ere t&e

more e-otic material are ued/ T&ee material are reuired to perform a 6ide

1ariety of function2 including t&e &ip propulion ytem2 4ac3.up po6er2

3itc&en2 pump tation for fuel tranfer and com4at ytem/

Steel ued for contruction can 4e u4di1ided into t&ree type% mild2 &ig&.trengt&

and &ig&.alloy teel/ #ild teel &a1e 1alua4le propertie and are eay to produce2

purc&ae2 form and 6eld/ 0n t&e ot&er &and2 &ig&.trengt& teel are mildly alloyedto pro1ide mec&anical propertie t&at are uperior to t&e mild teel/ E-tremely

&ig&.trengt& teel &a1e 4een de1eloped pecifically for ue in na1al contruction/

In general2 t&e &ig&.trengt& and &ig&.yield teel are called @Y.)2 @Y.$)) and

@Y.$*)/ T&ey &a1e trengt& propertie in e-ce of t&e commercial.grade &ig&.

trengt& teel/ #ore complicated 6elding procee are neceary for &ig&.



trengt& teel in order to pre1ent deterioration of t&eir propertie/ Specific 6eld

rod are needed for &ig&.trengt& teel2 and 6eld !oint &eating =pre&eating? i

uually reuired/ A t&ird general cla of teel2 t&e &ig&.alloy teel2 are made 4y

including relati1ely large amount of alloying element uc& a nic3el2 c&romium

and manganee/ T&ee teel2 6&ic& include tainle teel2 &a1e 1alua4lecorroion.reitance propertie and alo reuire pecial 6elding procee/

Steel i an e-cellent material for &ip4uilding purpoe2 and t&e c&oice of 6elding

electrode i critical in all 6elding application during contruction/ T&e tandard

goal i to o4tain a 6eld 6it& eui1alent trengt& c&aracteritic to t&at of t&e 4ae

metal/ Since minor fla6 are li3ely to occur in production 6elding2 6eld are often

deigned and 6elding electrode c&oen to produce 6eld 6it& propertie in e-ce

of t&oe of t&e 4ae metal/

Aluminum &a found increaed application a a &ip4uilding metal due to it &ig&trengt&.to.6eig&t ratio compared to teel/ Alt&oug& t&e ue of aluminum for &ull

&a 4een limited2 aluminum upertructure are 4ecoming more common for 4ot&

military and merc&ant &ip contruction/ Veel made olely from aluminum are

primarily maller.i9ed 4oat2 uc& a fi&ing 4oat2 pleaure 4oat2 mall

paenger 4oat2 gun4oat and &ydrofoil/ T&e aluminum ued for &ip4uilding and

repair i generally alloyed 6it& manganee2 magneium2 ilicon andBor 9inc/ T&ee

alloy offer good trengt&2 corroion reitance and 6elda4ility

<elding intead of ri1et

S&ipyard 6elding procee2 or more pecifically fuion 6elding2 i performed at

nearly e1ery location in t&e &ipyard en1ironment/ T&e proce in1ol1e !oining

metal 4y 4ringing ad!oining urface to e-tremely &ig& temperature to 4e fued

toget&er 6it& a molten filler material/ A &eat ource i ued to &eat t&e edge of t&e

!oint2 permitting t&em to fue 6it& molten 6eld fill metal =electrode2 6ire or rod?/

T&e reuired &eat i uually generated 4y an electric arc or a ga flame/ S&ipyard

c&ooe t&e type of 6elding proce 4aed on cutomer pecification2 productionrate and a 1ariety of operating contraint including go1ernment regulation/

Standard for military 1eel are uually more tringent t&an commercial 1eel/

An important factor 6it& repect to t&e fuion.6elding procee i arc &ielding to

protect t&e 6eld pool/ T&e temperature of t&e 6eld pool i u4tantially &ig&er t&an

t&e ad!oining metalH melting point/ At e-tremely &ig& temperature2 a reaction



6it& o-ygen and nitrogen in t&e atmop&ere i rapid and &a negati1e effect on t&e

6eld trengt&/ S&ould o-ygen and nitrogen from t&e atmop&ere 4ecome trapped

6it&in t&e 6eld metal and molten rod2 em4rittlement of t&e 6eld area 6ill occur/

To protect againt t&i 6eld impurity and enure 6eld uality2 &ielding from t&e

atmop&ere i reuired/ In mot 6elding procee2 &ielding i accompli&ed 4yaddition of a flu-2 a ga or a com4ination of t&e t6o/ <&ere a flu- material i ued2

gae generated 4y 1apori9ation and c&emical reaction at t&e electrode tip reult in

a com4ination of flu- and ga &ielding t&at protect t&e 6eld from nitrogen and

o-ygen entrapment/ S&ielding i dicued in t&e follo6ing ection2 6&ere

pecific 6elding procee are decri4ed/

In electric arc 6elding2 a circuit i created 4et6een t&e 6or3.piece and an electrode

or 6ire/ <&en t&e electrode or 6ire i &eld a &ort ditance a6ay from t&e 6or3.

piece2 a &ig&.temperature arc i created/ T&i arc generate ufficient &eat to melt

t&e edge of t&e 6or3.piece and t&e tip of t&e electrode or 6ire to produce a fuion.

6elding ytem/ T&ere are a num4er of electric arc 6elding procee uita4le for

ue in &ip4uilding/ All procee reuire &ielding of t&e 6eld area from t&e

atmop&ere/ T&ey may 4e u4di1ided into flu-.&ielded and ga.&ielded

procee/

#anufacturer of 6elding euipment and aociated conuma4le and non.

conuma4le product report t&at arc 6elding 6it& conuma4le electrode i t&e

mot uni1eral 6elding proce/

S&ielded metal arc 6elding =S#A<?/ Flu-.&ielded electric arc 6elding procee

are ditingui&ed primarily 4y t&eir manual or emi.automatic nature and t&e type

of conuma4le electrode ued/ T&e S#A< proce utili9e a conuma4le electrode

=*)/+ to , cm in lengt&? 6it& a dry flu- coating2 &eld in a &older and fed to t&e

6or3.piece 4y t&e 6elder/ T&e electrode conit of t&e olid metal filler rod core2

made from eit&er dra6n or cat material co1ered 6it& a &eat& of metal po6der/

S#A< i alo freuently referred to a tic3 6elding and arc 6elding/ T&e

electrode metal i urrounded 4y flu- t&at melt a 6elding progree2 co1ering

t&e depoited molten metal 6it& lag and en1eloping t&e immediate area in an

atmop&ere of protecti1e ga/ #anual S#A< may 4e ued for do6n &and =flat?2

&ori9ontal2 1ertical and o1er&ead 6elding/ S#A< procee may alo 4e ued

emi.automatically t&roug& t&e ue of a gra1ity 6elding mac&ine/ Gra1ity

mac&ine ue t&e 6eig&t of t&e electrode and &older to produce tra1el along t&e

6or3.piece/



Su4merged arc 6elding =SA<? i anot&er flu-.&ielded electric arc 6elding

proce ued in many &ipyard/ In t&i proce2 a 4lan3et of granulated flu- i

depoited on t&e 6or3.piece2 follo6ed 4y a conuma4le 4are metal 6ire electrode/

Generally2 t&e electrode er1e a t&e filler material2 alt&oug& in ome cae metal

granule are added to t&e flu-/ T&e arc2 u4merged in t&e 4lan3et of flu-2 melt t&eflu- to produce a protecti1e inulated molten &ield in t&e 6eld 9one/ @ig& &eat

concentration permit &ea1y 6eld depoit at relati1ely &ig& peed/ After 6elding2

t&e molten metal i protected 4y a layer of fued flu-2 6&ic& i u4euently

remo1ed and may 4e reco1ered/ Su4merged arc 6elding mut 4e performed do6n

&and and i ideally uited to 4utt 6elding plate toget&er on panel line2 platen

area and erection area/ T&e SA< proce i generally fully automatic2 6it&

euipment mounted on a mo1ing carriage or elf.propelled platform on top of t&e

6or3.piece/ Since t&e SA< proce i primarily automatic2 a good portion of time

i pent aligning t&e 6eld !oint 6it& t&e mac&ine/ Similarly2 ince t&e SA< arcoperate under a co1ering of granulated flu-2 t&e fume generation rate =FGR? or

fume formation rate =FFR? i lo6 and 6ill remain contant under 1ariou operating

condition pro1ided t&at t&ere i adeuate flu- co1er/

Ga metal arc 6elding =G#A<?/ Anot&er ma!or category of electric arc 6elding

comprie t&e ga.&ielded procee/ T&ee procee generally ue 4are 6ire

electrode 6it& an e-ternally upplied &ielding ga 6&ic& may 4e inert2 acti1e or a

com4ination of t&e t6o/ G#A<2 alo commonly referred to a metal inert ga

=#IG? 6elding2 ue a conuma4le2 automatically fed2 mall.diameter 6ire

electrode and ga &ielding/ G#A< i t&e an6er to a long.oug&t met&od of

4eing a4le to 6eld continuouly 6it&out t&e interruption of c&anging electrode/

An automatic 6ire feeder i reuired/ A 6ire pooling ytem pro1ide an

electrodeB6ire filler rate t&at i at a contant peed2 or t&e peed fluctuate 6it& a

1oltage enor/ At t&e point 6&ere t&e electrode meet t&e 6eld arc2 argon or

&elium 4eing ued a t&e &ielding ga i upplied 4y t&e 6elding gun/ It 6a found

t&at for 6elding teel2 a com4ination of 80" andBor an inert ga could 4e ued/

0ften2 a com4ination of t&e gae i ued to optimi9e cot and 6eld uality/

Ga tungten arc 6elding =GTA<?/ Anot&er type of ga.&ielded 6elding procei ga tungten arc 6elding2 ometime referred to a tungten inert ga =TIG?

6elding or t&e trade name @eliarc2 4ecaue &elium 6a initially ued a t&e

&ielding ga/ T&i 6a t&e firt of t&e ne6 6elding procee2 follo6ing tic3

6elding 4y a4out "+ year/ T&e arc i generated 4et6een t&e 6or3.piece and a

tungten electrode2 6&ic& i not conumed/ An inert ga2 uually argon or &elium2



pro1ide t&e &ielding and pro1ide for a clean2 lo6.fume proce/ Alo2 t&e

GTA< proce arc doe not tranfer t&e filler metal2 4ut imply melt t&e material

and t&e 6ire2 reulting in a cleaner 6eld/ GTA< i mot often employed in

&ipyard for 6elding aluminum2 &eet metal and mall.diameter pipe and tu4e2

or to depoit t&e firt pa on a multi.pa 6eld in larger pipe and fitting/

Flu- core arc 6elding =F8A<? ue euipment imilar to G#A< in t&at t&e 6ire

i fed continuouly to t&e arc/ T&e main difference i t&at t&e F8A< electrode i a

tu4ular electrode 6ire 6it& a flu- core centre t&at &elp 6it& locali9ed &ielding in

t&e 6elding en1ironment/ Some flu- cored 6ire pro1ide adeuate &ielding 6it&

t&e flu- core alone/ @o6e1er2 many F8A< procee ued in t&e &ip4uilding

en1ironment reuire t&e addition of ga &ielding for t&e uality reuirement of

t&e &ip4uilding indutry/

T&e F8A< proce pro1ide a &ig&.uality 6eld 6it& &ig&er production rate and6elder efficiency t&an t&e traditional S#A< proce/ T&e F8A< proce allo6

for a full range of production reuirement2 uc& a o1er&ead and 1ertical 6elding/

F8A< electrode tend to 4e a little more e-peni1e t&an S#A< material2

alt&oug& in many cae increaed uality and producti1ity are 6ort& t&e

in1etment/

Plama.arc 6elding =PA<?/ T&e lat of t&e &ielded ga 6elding procee i

plama.metal inert.ga 6elding/ PA< i 1ery imilar to t&e GTA< proce e-cept

t&at t&e arc i forced to pa t&roug& a retriction 4efore reac&ing t&e 6or3.piece/

T&e reult i a !et tream of intenely &ot and fat.mo1ing plama/ T&e plama i an

ioni9ing tream of ga t&at carrie t&e arc2 6&ic& i generated 4y contricting t&e

arc to pa t&roug& a mall orifice in t&e torc&/ PA< reult in a more concentrated2

&ig&.temperature arc2 and t&i permit fater 6elding/ Aide from t&e ue of t&e

orifice to accelerate t&e ga2 PA< i identical to GTA<2 uing a non.conuma4le

tungten electrode and an inert ga &ield/ PA< i generally manual and &a

minimal ue in &ip4uilding2 alt&oug& it i ometime ued for flame praying

application/ It i ued primarily for teel cutting in t&e &ip4uilding en1ironment

Ue of nic3el



Nic3el.containing product play an important role in our daily li1e/ 8ompared

6it& ot&er material2 nic3el.containing product poe 4etter corroion

reitance2 greater toug&ne2 and more trengt& at &ig& and lo6 temperature2 and

a range of pecial magnetic and electronic propertie/ T&erefore2 mot nic3el production i ued for alloying element2 coating2 4atterie2 and ome ot&er ue2

uc& a 3itc&en 6are2 mo4ile p&one2 medical euipment2 tranport2 4uilding2

po6er generation and !e6ellery/

T&e ue of nic3el i dominated 4y t&e production of ferronic3el for

tainle teel =>?/ @o6e1er2 it i alo ued in t&e production of non.ferrou

alloy =$">?2 alloy teel =+>?2 plating =J>?2 foundry =*>? and 4atterie =">?/

Nic3el can alloy 6it& teel2 iron2 copper2 c&romium2 aluminum2 lead2 co4alt2

il1er2 gold and ot&er element to ma3e tainle teel2 cat iron2 inconel2 incoloy2monel2 nimonic and ot&er alloy/ Detailed alloyH claification are a follo6%

Ferrou alloy include tainle teel2 lo6 alloy teel2 cat iron and ome

pecialty teel/ T&e product are ued in ga tur4ine2 ome c&emical plant2

coinage and marine engineering/

T&e mot 6idely ued non.ferrou alloy are copper alloy uc& a monel2 nic3el

4rae and 4ron9e/ T&e product include propeller2 cran3&aft and &ull of

premium tug4oat2 fi&ing 4oat and ot&er 6or3ing 4oat

Nic3el.4ae alloy include Ni.4ae uperalloy2 Ni.4ae corroion reitant alloy2

Ni.4ae 6ear.reitant alloy2 Ni.4aed preciion alloy2 Ni.4ae &ape memory alloy

and @ydrogen toring alloy/ T&e a4o1e alloy are 6idely ued in a1iation2

&ip4uilding2 t&e c&emical indutry2 electronic2 medicine and t&e energy indutry/

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engineering material assignment