the costs of non testing - confederation of european ......the costs of non testing d. gillissen...
TRANSCRIPT
![Page 1: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/1.jpg)
Ruimte voor uw eigen logo!
The costs of Non Testing
D. GillissenStork FDO
![Page 2: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/2.jpg)
Ruimte voor uw eigen logo!
Stork Materials Technology
An operating company within the Stork Technical Services Group
![Page 3: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/3.jpg)
Ruimte voor uw eigen logo!
Core activities
• Material testing• Non destructive
testing• Calibration• Consultancy
![Page 4: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/4.jpg)
Ruimte voor uw eigen logo!
Materials testing• Mechanical testing ( -80ºC to + 900ºC)
• Bearing strength
• Poisson's ratio
• Tensile, peel and tear
• Bending fatigue
• Special tests
![Page 5: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/5.jpg)
Ruimte voor uw eigen logo!
Consultancy
• Applied mechanics
• Strain and stress measurements
• Failure calculations
• Vibration measurements
• Product testing and evaluations
• Sound measurements
![Page 6: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/6.jpg)
Ruimte voor uw eigen logo!
Consultancy• Corrosion
• Exposition tests
• SSCC tests
• Corrosion potential measurements
• HIC tests
• Etc.
![Page 7: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/7.jpg)
Ruimte voor uw eigen logo!
ConsultancyFailure analyses
• Failure mechanism
• Failure cause
• Repair procedures
• Failure prevention
![Page 8: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/8.jpg)
Ruimte voor uw eigen logo!
Experiences of non testing and the consequences
• Testing after or during production• Proven knowledge and changing of the
environment• Designing with stronger materials• Lighter construction and the role of
fatigue• Upgrading of components• Applying new techniques
![Page 9: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/9.jpg)
Ruimte voor uw eigen logo!
Testing after production• Industrial components
short delivery times• Test is frequently done
during production• The results are not
according specification• The manufacturer has a
lot of cost and effort to repair the vessel and find back the confidence
![Page 10: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/10.jpg)
Ruimte voor uw eigen logo!
Example of a pressure vessel
• HIC test for Hydrogen induced cracking
• Test failed• Vessel subjected to
be rejected by the client
![Page 11: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/11.jpg)
Ruimte voor uw eigen logo!
Designing based on proven knowledge
• Swimming pools upgraded to leisure pools
• Trent higher temperatures in in the hall
• Higher level of chemicals for disinfection
• Frequently used materials are subjected to stress corrosion cracking
• Result
![Page 12: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/12.jpg)
Ruimte voor uw eigen logo!
In 2001, the suspended ceiling of a municipal swimming pool
collapsed. The reason was the catastrophic failure of stainless
steel grade 304 fasteners, which had suffered stress corrosion
cracking (SCC)
![Page 13: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/13.jpg)
Ruimte voor uw eigen logo!
Situation after incident
![Page 14: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/14.jpg)
Ruimte voor uw eigen logo!
Microscopic examination
![Page 15: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/15.jpg)
Ruimte voor uw eigen logo!
Actions and costs
• Inspection of at least 30 swimming pools with the same construction
• Later on more swimming pools were inspected
• Most of the ceiling have to be replaced• New design criteria had to be made
![Page 16: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/16.jpg)
Ruimte voor uw eigen logo!
Designing with stronger materials
• Tension bar in gas handling equipment• Tension shall be increased to ensure
stiffness• Material with higher tensile strength• Result failure during test• Failure analyses shows hydrogen
induced cracking from a corrosion process
![Page 17: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/17.jpg)
Ruimte voor uw eigen logo!
![Page 18: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/18.jpg)
Ruimte voor uw eigen logo!
Lesson
• High cost for the failure of a very expensive piece of equipment
• Material is not suitable for this application• Searching for new material• If no material is available design shall be
changed• Test program for the new selected material
![Page 19: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/19.jpg)
Ruimte voor uw eigen logo!
Lighter constructions
• Aluminum is one of the favorable materials to decrease weight
• Lighter construction lower forces• Fatigue strength is lower• Some processes reduces fatigue
![Page 20: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/20.jpg)
Ruimte voor uw eigen logo!
Example
• Support roll• Material changed into aluminum• To improve wear resistance a hard
anodizing coating was applied• Fracture in short time notice
![Page 21: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/21.jpg)
Ruimte voor uw eigen logo!
Location of fracture
![Page 22: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/22.jpg)
Ruimte voor uw eigen logo!
Examination Scanning Electron Microscope
Initiation point
![Page 23: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/23.jpg)
Ruimte voor uw eigen logo!
Failure cause
• Cracks in the hard anodized layer
• Reduction of fatigue strength especially by high strength aluminum after hard anodizing
![Page 24: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/24.jpg)
Ruimte voor uw eigen logo!
Effects of anodizing on fatigue strength
Alloy Fatigue strength at E10-6 cyclesNot anodized Anodized
MPa MPA2024 130 1056061 105 407075 150 60
![Page 25: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/25.jpg)
Ruimte voor uw eigen logo!
Lessons
• Although extensive calculations failure• Hard anodizing caused a lower fatigue
strength as expected• Testing should have tracked this
abnormality• All produced and built in supports shall be
replaced
![Page 26: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/26.jpg)
Ruimte voor uw eigen logo!
Upgrading of components
• Upgrading of machinery requires thicker materials
• Three axial stress conditions can play a role
• These stress conditions are difficult to establish even with Finite elements
![Page 27: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/27.jpg)
Ruimte voor uw eigen logo!
Example Fluid Forming Press
Rubber sheetMetal sheet
Oil pressure
clamp
Clamp failure
1500 mm
450 mm
![Page 28: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/28.jpg)
Ruimte voor uw eigen logo!
History of the clamp rings
• First statically calculated two halves
• Failure in two weeks• Design adapted
according finite element analyses
• Key hole design • Lifetime 3 months
![Page 29: The costs of Non Testing - Confederation of European ......The costs of Non Testing D. Gillissen Stork FDO. Ruimte voor uw eigen logo! Stork Materials Technology An operating company](https://reader031.vdocuments.net/reader031/viewer/2022011902/5f0c851a7e708231d435d00a/html5/thumbnails/29.jpg)
Ruimte voor uw eigen logo!
New design
• Clamp ring built in segments
• Three axial forces are lower
• Lifetime over 10 years
Possibility to contract