Analisis Kegagalan Material Ceramic Tube Thermocouple Pada Mesin Tunnel Kiln Pabrik 2. (Failure Analysis of Ceramic Tube Thermocouple Material in Tunnel Kiln Machine Factory 2).

Prasetyo, Bagus (2026) Analisis Kegagalan Material Ceramic Tube Thermocouple Pada Mesin Tunnel Kiln Pabrik 2. (Failure Analysis of Ceramic Tube Thermocouple Material in Tunnel Kiln Machine Factory 2). Undergraduate thesis, Universitas 17 Agustus 1945 Surabaya.

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Abstract

Thermocouple is a temperature sensor that is widely used in high-temperature industrial processes, including in tunnel kiln machines. Ceramic Tube as a Thermocouple protector functions as an important function to maintain measurement accuracy and extend the service life of the sensor (Platinum – Rhodium). However, in operational conditions, ceramic materials often experience failures in the form of cracks, breaks, or structural degradation. This study aims to analyze the causes of Ceramic tube Thermocouple failure in tunnel kiln machines through operational data and material characterization approaches. The methods used include HMI (Human Machine Interface) observation, sensor distance measurement, vibration value measurement, NDT (Non-Destructive Test) testing, SEM (Scanning Electron Microscope), and EDS (Energy Dispersive Spectroscopy) analysis. The results of the study show that the sensor installation distance is positioned at 3 cm and geometrically there is still room from impact. Thermocouple holders in the firing zone have operational vibration fluctuations of up to 0.383 mm/s. Penetrant dye testing detects abnormal porosity at the end of the tube without any signs of cracked propagation in the surface area of the tube. The results of SEM fractography showed a dominant characteristic in the form of brittle fracture with an intergranular crack propagation pathway, accompanied by the presence of fine striation typical of mechanical fatigue. EDS analysis in areas indicated by contaminants detected infiltration of foreign elements in the form of Calcium (Ca) of 27.20% and Silica (Si) of 10.26%. The data sheet explains that Alumina C799 material is categorized as impermeable and very dense material with 0% water absorption. It can be concluded that the possible failure of the Ceramic Tube is caused by the mechanical fatigue factor due to the cyclic vibration of operation with a value fluctuation of 0.383 mm/s. As a preventive measure, it is recommended to add a vibration reducer in the form of a Ceramic Fiber Blanket to the Thermocouple holder and check the tunnel kiln train tracks during overholing.

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