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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

  1. FINAL PROJECT ِﻡﻱِﺡ.ﺭﻝﺍ ِﻥﻡْﺡ ُّ ﺭﻝﺍ ِ 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

  2. Final Project 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”

  3. Pendahuluan 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.

  4. Pendahuluan 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 of 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)?

  5. Pendahuluan 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 on 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)?

  6. Pendahuluan 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.

  7. MULAI Flowchart Penelitian Identifikasi Msalah Studi Literatur Penentuan Ukuran Test Coupon Pengujian Pengujian Pengelasan Material Uji (FCAW) Metalografi Tarik dan Hardness Pengujian Pengujian Pengelasan Ulang 1x Pengelasan Ulang 1x Pengujian Pengujian Metalografi Metalografi (FCAW) Tarik Tarik (SMAW) dan Hardness dan Hardness Pengujian Pengujian Pengelasan Ulang 2x Pengelasan Ulang 2x Pengujian Pengujian Metalografi Metalografi (FCAW) Tarik Tarik (SMAW) dan Hardness dan Hardness Pengujian Pengujian Pengelasan Ulang 3x Pengelasan Ulang 3x Pengujian Pengujian Metalografi Metalografi (FCAW) Tarik Tarik (SMAW) dan Hardness dan Hardness Pengujian Pengujian Pengelasan Ulang 4x Pengelasan Ulang 4x Pengujian Pengujian Metalografi Metalografi (FCAW) Tarik Tarik (SMAW) dan Hardness dan Hardness Pengolahan Hasil Uji (18 specimen) Analisa Kesimpulan

  8. Tinjauan Pustaka Mechanical Properties Duplex Stainless Steel 2205 Grade Tensile Str Yield Strength Elongation Hardness (% in 50mm) (Mpa) min 0.2% Proof min Rockwell C Brinell (HB) Vickers (HV) (Mpa) min (HR C) 2205 620 450 25 31 max 293 max 301.6 max

  9. Metodologi Specimen Procedure Test Specimen Dimension

  10. Metodologi Specimen Test Metalography Test Tensile Test Hardness Test (Vickers)

  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)

  12. Analisa Data & Pembahasan Weld Metal 2x repair (FCAW-SMAW) 3x repair (FCAW-SMAW) 4x repair (FCAW-SMAW) Fusion Line Without repair (FCAW) 1x repair (FCAW-FCAW) 2x repair (FCAW-FCAW)

  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)

  14. Analisa Data & Pembahasan Persen Weld Metal Variasi Pengelasan Ferrite Austenite A (normal) 46.23 53.77 WELD METAL FCAW-FCAW 90 80 B (1x repair) 48.57 51.43 70 C (2x repair) 51.31 48.69 60 % Ferrite FCAW-FCAW 50 D (3x repair) 66.23 33.77 40 FCAW-SMAW E (4x repair) 84.36 15.64 30 20 10 0 FCAW-SMAW 0 1 2 3 4 5 6 F (1x repair) 50.07 49.93 Variasi Re-welding G (2x repair) 50.83 49.17 H (3x repair) 52.84 47.16 Ferrite content (FCAW-FCAW) : I (4x repair) 62.90 37.10 - 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)

  15. Analisa Data& Pembahasan Persen Variasi Pengelasan Fusion Line Ferrite Austenite A (normal) 50.99 49.01 FUSION LINE FCAW-FCAW 100 90 B (1x repair) 55.16 44.84 80 70 C (2x repair) 57.08 42.92 % Ferrite 60 FCAW-FCAW D (3x repair) 75.46 24.54 50 FCAW-SMAW 40 E (4x repair) 86.63 13.37 30 20 10 0 FCAW-SMAW 0 1 2 3 4 5 6 F (1x repair) 53.65 46.35 Variasi Re-welding G (2x repair) 59.23 40.77 H (3x repair) 60.44 39.56 Ferrite content (FCAW-FCAW) : I (4x repair) 79.93 20.07 - 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)

  16. Analisa Data & Pembahasan Conclusion of Metalogaphy Test • 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.

  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)

  18. Analisa Data & Pembahasan G -2x repair (FCAW-SMAW) H -3x repair (FCAW-SMAW) I -4x repair (FCAW-SMAW) • Visible defects in the specimen E, specimen G, specimen I. • One cause of defects : welder factor, environment influence.

  19. Analisa Data & Pembahasan 3. Hardness Vickers Test The average hardness value of re-welding (FCAW-FCAW) Hardness Vickers (HV) Jumlah Pengelasan Ulang 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 The average hardness value of re-welding (FCAW-SMAW) 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

  20. Anslisa Data & Pembahasan Graph of hardness value in Weld Metal area WELD METAL 380.00 375.00 370.00 365.00 360.00 FCAW-FCAW HV 355.00 FCAW-SMAW 350.00 345.00 340.00 335.00 330.00 0 1 2 3 4 5 6 Variasi Re-welding Graph of hardness value in Fusion Line area FUSION LINE 400.00 390.00 380.00 370.00 FCAW-FCAW HV 360.00 FCAW-SMAW 350.00 340.00 330.00 320.00 0 1 2 3 4 5 6 Variasi Re-welding

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

  22. Analisa Data & Pembahasan 4. Tensile Test Specification sample Tensile test result Width Thick ( ( F Yield No. Variasi Pengelasan Breaking m m CSA (k UTS m m (m F Ultimate N (M Yield strength ) ) m²) (kN) ) Pa) (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 Tensile test result

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