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FINAL PROJECT . By Novita Judha Kusumastuti 4106 100 004 Supervisor by Wing Hendroprasetyo. A.P, S.T, M.Eng Ir. Soeweify, M.Eng DEPARTMENT OF NAVAL ARCHITECTURE

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SLIDE 1

ِﻡﻱِﺡ.ﺭﻝﺍ ِﻥﻡْﺡُّﺭﻝﺍ ِاللو ِﻡْﺱِﺏ

By Novita Judha Kusumastuti 4106 100 004 Supervisor by Wing Hendroprasetyo. A.P, S.T, M.Eng

  • Ir. Soeweify, M.Eng

DEPARTMENT OF NAVAL ARCHITECTURE & SHIP BUILDING FACULTY OF OCEAN TECHNOLOGY SEPULUH NOPEMBER INSTITUTE OF TECHNOLOGY 2010

FINAL PROJECT

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SLIDE 2

ANALYSIS OF CHANGES OF MECHANICAL PROPERTIES AND MICRO STRUCTURE IN THE RE-WELDING PROCESS (FCAW-FCAW AND FCAW-SMAW) “CASE STUDY OF THE CHEMICAL TANKER CARGO SHIP TANK BUTT-JOINT WELDING OF DUPLEX STAINLESS STEEL 2205 MATERIALS”

Final Project

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SLIDE 3

Background

  • Duplex Stainless Steel 2205 Materials, is widely used as the main

material in the production process, especially in the Cargo Tank of Chemical Tanker Vessel.

  • This is because the Duplex Stainless Steel 2205 has the advantages are:

high strength, corrosion resistance, resistance to fatique, has a low thermal expansion and having weldability and able to weld a good shape.

  • Connect the ship construction (welding) with Duplex Stainless Steel

2205 materials using welding process FCAW (Flux Cored Arc Welding). When needed repairing caused any welding defect, then at the welded joints will be re-welded.

  • In reality on board (the shipyard), there are two kinds of re-welding

process that can be applied to weld Duplex Stainless Steel 2205, i.e. re- weld using FCAW process (equal to the initial welding) and the second with re-welding of SMAW process.

Pendahuluan

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SLIDE 4

Problem Formulation

1. How the influence re-welding on microstructure and mechanical properties on welding connection of Duplex Stainless Steel 2205? 2. How the influence of different numbers of re- welding on mechanical properties and microstructure

  • f Duplex Stainless Steel 2205?

3. How differences of microstructure and mechanical properties of the welding result due to re-welding (FCAW–FCAW and FCAW–SMAW)?

Pendahuluan

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SLIDE 5

Objective

  • Knowing the influence of re-welding (FCAW–

FCAW and FCAW–SMAW) in Duplex Stainless Steel 2205 material in terms of mechanical properties and microstructure.

  • Knowing the influence of the number of re-welding
  • n mechanical properties and microstructure of

Duplex Stainless Steel 2205.

  • Knowing how big the difference in the

microstructure and mechanical properties of the welding result due to re-welding (FCAW–FCAW and FCAW–SMAW)?

Pendahuluan

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SLIDE 6

Benefit

To know the changes and differences that occur in re-welding (FCAW– FCAW and FCAW–SMAW) on mechanical properties and microstructure of Duplex Stainless Steel 2205.

Pendahuluan

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SLIDE 7

MULAI Identifikasi Msalah Studi Literatur Penentuan Ukuran Test Coupon Pengelasan Material Uji (FCAW) Pengelasan Ulang 1x (FCAW) Pengelasan Ulang 1x (SMAW) Kesimpulan Pengolahan Hasil Uji (18 specimen) Analisa Pengelasan Ulang 3x (FCAW) Pengelasan Ulang 2x (FCAW) Pengelasan Ulang 2x (SMAW) Pengelasan Ulang 3x (SMAW)

Pengujian Metalografi dan Hardness Pengujian Metalografi dan Hardness Pengujian Metalografi dan Hardness Pengujian Metalografi dan Hardness Pengujian Metalografi dan Hardness Pengujian Metalografi dan Hardness Pengujian Metalografi dan Hardness Pengujian Tarik Pengujian Tarik Pengujian Tarik Pengujian Tarik Pengujian Tarik Pengujian Tarik Pengujian Tarik

Pengelasan Ulang 4x (FCAW)

Pengujian Metalografi dan Hardness Pengujian Tarik

Pengelasan Ulang 4x (SMAW)

Pengujian Tarik Pengujian Metalografi dan Hardness

Flowchart Penelitian

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SLIDE 8

Mechanical Properties Duplex Stainless Steel 2205

Tinjauan Pustaka

Grade Tensile Str Yield Strength Elongation Hardness (Mpa) min 0.2% Proof (% in 50mm) min Rockwell C Brinell (HB) Vickers (HV) (Mpa) min (HR C) 2205 620 450 25 31 max 293 max 301.6 max

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SLIDE 9

Metodologi

Specimen Procedure

Test Specimen Dimension

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SLIDE 10

Specimen Test

Metalography Test Tensile Test Hardness Test (Vickers)

Metodologi

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SLIDE 11

Analisa Data & Pembahasan

  • 1. Metalography Test (Micro Photograph)

Weld Metal

Without repair (FCAW) 1x repair (FCAW-FCAW) 2x repair (FCAW-FCAW) 3x repair (FCAW-FCAW) 4x repair (FCAW-FCAW) 1x repair (FCAW-SMAW)

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SLIDE 12

Analisa Data & Pembahasan

Weld Metal Fusion Line

2x repair (FCAW-SMAW) 3x repair (FCAW-SMAW) 4x repair (FCAW-SMAW) Without repair (FCAW) 1x repair (FCAW-FCAW) 2x repair (FCAW-FCAW)

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SLIDE 13

Analisa Data & Pembahasan

Fusion Line

3x repair (FCAW-FCAW) 4x repair (FCAW-FCAW) 1x repair (FCAW-SMAW) 2x repair (FCAW-SMAW) 3x repair (FCAW-SMAW) 4x repair (FCAW-SMAW)

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SLIDE 14

Analisa Data & Pembahasan

Variasi Pengelasan Persen Ferrite Austenite A (normal) 46.23 53.77 FCAW-FCAW B (1x repair) 48.57 51.43 C (2x repair) 51.31 48.69 D (3x repair) 66.23 33.77 E (4x repair) 84.36 15.64 FCAW-SMAW F (1x repair) 50.07 49.93 G (2x repair) 50.83 49.17 H (3x repair) 52.84 47.16 I (4x repair) 62.90 37.10

Weld Metal

Ferrite content (FCAW-FCAW) :

  • Max : 84,36 % Specimen E (4x repair)

Ferrite content (FCAW-SMAW) :

  • Max : 62,90 % Specimen I (4x repair)

Ferrite content Min : 46,23 % Specimen A (normal)

WELD METAL

10 20 30 40 50 60 70 80 90 1 2 3 4 5 6 Variasi Re-welding % Ferrite FCAW-FCAW FCAW-SMAW

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SLIDE 15

Analisa Data& Pembahasan

Variasi Pengelasan Persen Ferrite Austenite A (normal) 50.99 49.01 FCAW-FCAW B (1x repair) 55.16 44.84 C (2x repair) 57.08 42.92 D (3x repair) 75.46 24.54 E (4x repair) 86.63 13.37 FCAW-SMAW F (1x repair) 53.65 46.35 G (2x repair) 59.23 40.77 H (3x repair) 60.44 39.56 I (4x repair) 79.93 20.07

Fusion Line

Ferrite content (FCAW-FCAW) :

  • Max : 86,63 % Specimen E (4x repair)

Ferrite content (FCAW-SMAW) :

  • Max : 79,93 % Specimen I (4x repair)

Ferrite content min : 50,99 % Specimen A (normal)

FUSION LINE

10 20 30 40 50 60 70 80 90 100 1 2 3 4 5 6 Variasi Re-welding % Ferrite FCAW-FCAW FCAW-SMAW

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SLIDE 16
  • Heat caused by re-welding resulted in changes in ferrite

content.

  • The more re-welding, that the more of ferrite content in

the materials.

  • As a result the materials becomes brittle.

Analisa Data & Pembahasan

Conclusion of Metalogaphy Test

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SLIDE 17

Analisa Data & Pembahasan

  • 2. Macro Photograph

A -Without repair (FCAW) B -1x repair (FCAW-FCAW) C -2x repair (FCAW-FCAW) D -3x repair (FCAW-FCAW) E -4x repair (FCAW-FCAW) F -1x repair (FCAW-SMAW)

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SLIDE 18

G -2x repair (FCAW-SMAW) H -3x repair (FCAW-SMAW) I -4x repair (FCAW-SMAW) Analisa Data & Pembahasan

  • Visible defects in the specimen E, specimen G, specimen I.
  • One cause of defects : welder factor, environment influence.
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SLIDE 19
  • 3. Hardness Vickers Test

Jumlah Pengelasan Ulang Hardness Vickers (HV) Base Metal Fusion Line Weld Metal Normal 333.67 331.00 336.33 1x repair 333.67 354.00 338.67 2x repair 333.67 355.67 340.00 3x repair 333.67 360.00 364.67 4x repair 333.67 390.67 374.33 Hardness Vickers (HV) Jumlah Pengelasan Ulang Base Metal Fusion Line Weld Metal Normal 333.67 331.00 336.33 1x repair 333.67 346.33 332.67 2x repair 333.67 335.67 336.33 3x repair 333.67 374.67 343.00 4x repair 333.67 386.00 351.67

Analisa Data & Pembahasan The average hardness value of re-welding (FCAW-FCAW) The average hardness value of re-welding (FCAW-SMAW)

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SLIDE 20

Anslisa Data & Pembahasan Graph of hardness value in Weld Metal area Graph of hardness value in Fusion Line area

WELD METAL

330.00 335.00 340.00 345.00 350.00 355.00 360.00 365.00 370.00 375.00 380.00 1 2 3 4 5 6 Variasi Re-welding HV FCAW-FCAW FCAW-SMAW

FUSION LINE

320.00 330.00 340.00 350.00 360.00 370.00 380.00 390.00 400.00 1 2 3 4 5 6 Variasi Re-welding HV FCAW-FCAW FCAW-SMAW

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SLIDE 21
  • Hardness value of material being increase cause re-welding.
  • Increasing of ferrite content cause re-welding make the materials

more brittle. Analisa Data & Pembahasan

Conclusion Hardness Vickers Test

Hardness value max (FCAW-FCAW) :

  • Weld metal : 374,33 HV Specimen E (4x repair)
  • Fusion line : 390,67 HV Specimen E (4x repair)

Hardness value max (FCAW-SMAW) :

  • Weld metal : 351,67 HV Specimen I (4x repair)
  • Fusion line : 386,00 HV Specimen I (4x repair)
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SLIDE 22

Analisa Data & Pembahasan

No. Variasi Pengelasan Specification sample Tensile test result Breaking Width ( m m ) Thick ( m m ) CSA (m m²) F Ultimate (kN) F Yield (k N ) UTS (M Pa) Yield strength (MPa) 1 A (normal) 19 10 190.00 139.00 102.50 731.58 539.47 Base Metal FCAW-FCAW 2 B (1x repair) 19.3 10 193.00 138.40 106.00 717.10 549.22 Base Metal 3 C (2x repair) 19.17 10 191.70 135.00 106.00 704.23 552.95 Base Metal 4 D (3x repair) 19.04 10 190.40 134.50 103.00 706.41 540.97 Base Metal 5 E (4x repair) 19.2 10 192.00 134.20 105.00 698.96 546.88 Base Metal FCAW-SMAW 6 F (1x repair) 19.1 10 191.00 136.00 107.00 712.04 560.21 Base Metal 7 G (2x repair) 19.15 10 191.50 133.00 101.00 694.52 527.42 Weld Metal 8 H (3x repair) 19.00 10 190.00 125.50 102.00 660.53 536.84 Base Metal 9 I (4x repair) 19.15 10 191.50 124.00 105.00 647.52 548.30 Weld Metal

  • 4. Tensile Test

Tensile test result

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SLIDE 23

Analisa Data & Pembahasan

Conclusion Tensile Test

  • Breaking the specimen (in Base Metal) caused by the difference of

mechanical properties between base metal and filler metal.

  • Tensile Strength on base metal 620 MPa

filler metal 810 MPa (FCAW) filler metal 794 MPa (SMAW)

  • Breaking the specimen (in Weld Metal) caused being to surface defects that
  • ccur in the specimen G and specimen I.
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General Conclusion

1. Analysis micro photograph : FCAW-FCAW (Increase value of ferrite content)

  • Weld metal max : 11,13 %
  • Fusion Line max : 10,57 %

FCAW-SMAW (Increase value of ferrite content)

  • Weld metal max : 7,17 %
  • Fusion line max : 8,09 %

2. Analysis Hardness Test : FCAW-FCAW (Increase value percentage of hardness)

  • Weld metal max : 2,72 %
  • Fusion Line max : 3,21 %

FCAW-SMAW (Increase value percentage of hardness)

  • Weld metal max : 1,17 %
  • Fusion line max : 3,58 %

Kesimpulan & Saran

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SLIDE 25

General Conclusion

3. Analyisis Tensile Test : FCAW-FCAW

  • Tensile str min : 698,96 MPa Specimen E (4x repair)

FCAW-SMAW

  • Tensile str min : 647,52 MPa Specimen I (4x repair)

_ - Tensile str max : 731,58 MPa Specimen A (normal) 4. The more re-welding

  • More increase ferrite content Hot crack

Weldability Corrosion resistent

  • More increase hardness value

5. Tensile strength values did not result in significant changes in the re-welding materials of Duplex Stainless Steel in 2205. 6. The re-welding FCAW-SMAW is better on the microstructure and mechanical properties of welding material than re-welding FCAW-FCAW.

Kesimpulan & Saran

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SLIDE 26

Thank You