Metallurgical Investigation of a Modified Eye Bolt Failure Caused by Improper Weld Extension, Specification Deviation, and Crevice Corrosion

Authors

• Dimas Muhammad Fawwaz, Department of Metallurgical and Materials Engineering, Faculty of Engineering, Universitas Indonesia, Depok, West Java, 16424, IndonesiaFollow
• Reza Miftahul Ulum, Department of Metallurgical and Materials Engineering, Faculty of Engineering, Universitas Indonesia, Depok, West Java, 16424, IndonesiaFollow
• Johny Wahyuadi Soedarsono, Department of Metallurgical and Materials Engineering, Faculty of Engineering, Universitas Indonesia, Depok, West Java, 16424, IndonesiaFollow
• Yudha Pratesa, Department of Metallurgical and Materials Engineering, Faculty of Engineering, Universitas Indonesia, Depok, West Java, 16424, IndonesiaFollow

Abstract

A modified eye bolt from the David Arm Manhole Storage Tank underwent thorough metallurgical study due to the consequences of the bolt's malfunction during operation. Safety issues arose when the manhole door detached during operation. The mechanical testing and chemical composition analysis of the bolts indicated they were manufactured from an ASTM A193 Grade B7 material used for high-temperature bolting. This material did not conform to the engineering drawing, which mentioned SA 563A, which is about nuts, not bolts. This contradiction clearly shows that the eye bolt which was installed does not conform to the intended design. Welded connections of two stud bolts were noted as the origin of the failures in the fractographic analysis. The metallographic pictures justified the observation of individual structures of the weld metal, heat-affected zone, and base metal. The welds had extensive porosities and slag inclusions, which are indicators of poor welds. Moreover, the welds not fully penetrating the metal workpieces also had the effect of reducing the load-bearing area. The joined sections also experienced crevice corrosion, which weakened the whole joint. The combination of poor welds and corrosion, which led to a cross-sectional loss of metal resulted in the eye bolt below the Manhole Door to be suddenly dropped.

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Recommended Citation

Fawwaz, Dimas Muhammad; Ulum, Reza Miftahul; Soedarsono, Johny Wahyuadi; and Pratesa, Yudha (2026) "Metallurgical Investigation of a Modified Eye Bolt Failure Caused by Improper Weld Extension, Specification Deviation, and Crevice Corrosion," Journal of Materials Exploration and Findings: Vol. 5: Iss. 2, Article 7.
DOI: 10.7454/jmef.v5i2.1133
Available at: https://scholarhub.ui.ac.id/jmef/vol5/iss2/7