Fundamental Theory of Damages

1 01/08/21
Introduction
•Damages are causes for the loss of functionability or

workability of a means of production, if proper action

is not taken against them.
•Even with optimum design and operation conditions

damages are unavoidable.

•Thus damages are the reasons for the existence of a

maintenance organization.
2 01/08/21
Classification of Damages

3 01/08/21
Reasons for damages
- Objective: Those are damages caused by
operational processes and environmental causes.
- Subjective: These are caused by failure in design,
manufacturing, use operation and maintenance.

4 01/08/21
Behaviors of Damages:
- Sudden behavior: use-value of equipment reduces
suddenly, in other words, sudden breakdown of
equipment takes place.
- Continuous behavior: use-value of equipment
decreases with time due to wear.

5 01/08/21
 Typical damages of equipment
1. Corrosion:
- Corrosion is the destruction or deterioration of materials by chemical or
electrochemical reaction with the environment. This includes the destruction of
metals in all types of atmospheres and liquids, and at any temperature.

- Corrosion is usually superficial but it sometimes is directed along grain

boundaries or other lines of weakness.
The Process of Corrosion
- Direct chemical Corrosion: is limited to conditions involving highly

corrosive environments or high temperature or both.

Examples: corrosion of metals left open in damp environments and at

high temperature; metals in contact with strong acids or alkalis.
6 01/08/21
- Electrochemical Corrosion: is characterized by
movement of metallic ions in solutions.
Examples: When zinc is placed in dilute
hydrochloride acid a vigorous reaction occurs,
hydrogen gas is evolved and zinc dissolves to
form zinc chloride.
This reaction can be divided into

7 anodic and cathode reactions. 01/08/21

 Kinds of Corrosion
A. Surface Corrosion ( uniform attack)
- most common form of corrosion, manifest over the
entire exposed surface or over a large area.

- Surface is destroyed nearly parallel to the surface.

- Caused by influence of ambient conditions on

unprotected metal surfaces.

- Metal becomes thinner and eventually may fail.

8 01/08/21
B. Pitting Corrosion:
- Pitting is one of the most destructive and dangerous forms
of corrosion.

- causes equipment failure because of perforation/hole with

only a small percent weight loss of entire equipment

- Difficult to detect because of their small size and often are

covered with corrosion products.

- Localized destruction of material (surface)

- It can take place below the surface affecting the stresses

9 01/08/21
(invisible).
C. Inter-crystalline Corrosion:
- Occurs at the grain boundary of metal alloys.

- Causes sudden crack.

D. Trans-crystalline Corrosion:
- Occurs through the grains of metal alloys.
E. Galvanic Corrosion (two-metal Corrosion)

- associated with the current of a galvanic cell made up of two dissimilar

metals.

- potential difference usually exists between two dissimilar metals when

they are immersed in a corrosive solution. If these metals are placed in
contact, the potential difference produces electron flow between them
and corrosion of the less corrosion resistant metal is increased. The less
10 01/08/21
resistant metal becomes anodic and the more resistant metal cathode.
 Factors that stimulate corrosion
 Atmospheric corrosion is stimulated by damp atmosphere,

since a film of water is maintained on the surface which is

an essential condition for corrosion
 Oxygen dissolved in water

 Acids, acid gases in the atmosphere, sulphur compounds,

coke, coal dust, etc.

 Salts that dissociate in water producing acid reactions

 Contact of dissimilar metals

11 01/08/21
 Cont.…
 Presence of depolarizing surfaces such as mill scale

 Non- uniformity within the metal

 Cold working process on metals results in increased rate of

attack by acids
 Fatigue stresses

 Rust may accelerate corrosion and cause pitting

 Corrosion on metals under stress is much more

severe than under ordinary conditions.
12 01/08/21
 Methods of minimizing corrosion

- Use of a coating of protective metal such as zinc, tin, lead, etc

- Application of protective paints

- Rendering the surface of the metal passive (immersing in nitric

acid after it has been highly poised immersing in fuming sulphuric
acid)
Corrosion problems are pronounced:
- Steam generating plants,
- Equipment's in chemical plants,
- Pipes, and
- Structures
13 01/08/21
 2. Wear
 Tribology is the science and technology of interacting surfaces

in relative motion which embraces the general concepts of all

aspects of the transmission and dissipation of energy.

Friction, wear, lubrication come under tribology

 Wear is undesired change of surface of machine components

by the removal of little particles caused by mechanical reasons.

Mostly wear is caused by friction of two mating parts.

14 01/08/21
 Conditions that must be fulfilled:
 Pair of wear partners, consisting of a basic body and a

mating body.

 Relative motion between the contacting surfaces.

 A normal force between the basis & mating bodies.

 Other factors.

15 01/08/21
 Kinds of wear
Depending on the motion we have
- Kinematics wear:-

- sliding - rolling - drilling - mixed

- Static wear

- Impact wear

16 01/08/21
Depending on time behavior of wear we have:-

- Stationary wear: Constant wear intensity over long time.

- Non-stationary wear: intensity depends on time.

17 01/08/21
 Mechanisms of wear:
A. Stress interactions
These are due to the combined action of load forces and
frictional forces

 Lead to wear processes namely:

Surface fatigue wear mechanism
Abrasive wear mechanism

18 01/08/21
 Surface fatigue wear mechanisms
- The effect of fatigue wear is especially associated with
repeated stress cycling in rolling contact, and is accompanied
by the generation and propagation of cracks.

-Surface fatigue effects are observed to occur in journal

bearings

19 01/08/21
Abrasive wear mechanisms
• Wear by abrasion is form of wear caused by contact
between a particle (grit) and solid material (the loss of
material by the passage of hard particles over a surface.)

20 01/08/21
B. Material interactions
 These are due to intermolecular forces either between the
interacting solid bodies or between the interacting solid
bodies and the environmental atmosphere.
 lead to wear processes described broadly as

Tribochemical reactions and

Adhesion.

21 01/08/21
 i. Tribochemical wear mechanisms
In tribochemical wear the dynamic interactions between the
material components and the environment determine the wear
process, where the environment is the third partner.

ii. Adhesive wear mechanisms

Adhesion is the ability of atomic structures to hold themselves

together and form surface bonds with other atoms or surfaces with
which they come into contact. The adhesive wear processes are
initiated by the interfacial adhesive junctions which form if solid
materials are in contact on an atomic scale. Material is then
transferred
22 due to adhesive joint formation which leads to rupture.
01/08/21
23 01/08/21
 Wear Processes
A. Shearing process

Roughness points will be sheared off if the acting forces are greater than the
shear strength. This leads to the reduction of roughness and increased percentage
of contact area which reduces energy concentration and wear velocity.

B. Elastic deformation

Big surface roughness result in low percentage of contact area and high energy
concentration in contact point. This may result in high local stresses. In the elastic
range this causes small flattening or bending of roughness points. Repetition of
this process will cause local fatigue of material.

24 01/08/21
C. Plastic deformation

If the local stress produced exceeds the elastic limit, plastic

deformation takes place in flattening and bending the
material (no loss in mass).

25 01/08/21
 Types of wear as related to lub application
Wear by Solid friction
 Solid friction occurs between the contacting surfaces

where there is no intermediate material

 In relation to the surface roughness we find wear process

by shearing, plastic and elastic deformation and heating of

the surfaces.

26 01/08/21
Wear by liquid friction
 The two mating bodies are completely separated from each other by

intermediate material, mostly a lubricant.

 Friction occurs in the lubricant, and wear is influenced by load,

relative velocity, temperature, viscosity of lubricant, the lubricating

gap

Wear by mixed friction

 Simultaneous action of solid + liquid friction, cause by high

roughness or high load for the lubricating film.

27This results in metallic contact . 01/08/21
 3. Fatigue
 Fatigue is the failure (or reduction in strength) of a material under
fluctuating stresses, which are repeated a very large number of
times.
 Fatigue failure begins with a hair-line crack which develops at a
point of discontinuity in the material (notches, groves, fillets,…).
 Once a small crack develops, it propagates under load to cause
failure.
 Components subjected to fluctuating forces must be designed for
fatigue conditions.
01/08/21 28
Surface conditions, residual stresses due to metal working processes
or metal - treating processes, stress concentration affect fatigue
strength very much. Hence, they should be considered properly at
design stage.
Fatigue strength (the endurance limit) of materials is greatly
decreased by the presence of a corroding medium.
Alternating stresses tend to cause considerable damage to any
protective film formed in the normal course of action of a corrosive
medium. Continual damage to this film may be a source of the further
development of cracks which accelerate fatigue failure.
01/08/21 29
 The End!!

01/08/21 30