E-mail: [email protected].

id

Hotel Santika Serpong, 27 Nopember 2018

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 BPPT IN A GLANCE
Agency for the Assessment and Application of Technology
Badan Pengkajian dan Penerapan Teknologi (BPPT)
2014- 2018
1974-1998
1998- 1998- 1999- 2001- 2004- 2006- 2008-
1998 1999 2001 2004 2006 2008 2014
Prof. Dr. Dr. Prof. Ir. Said
Prof. Dr. Dr. A.S. Ir. M. Hatta Kusmayanto Djauharsyah Dr. Ir. Marzan A.
Rahardi
Zuhal MSEE Hikam Rajasa Kadiman Iskandar
Ramelan Jenie, Sc.D Dr. Ir. Unggul
Prof. Dr.Ing. B.J. Priyanto, MSc
Habibie

Deputy For Technology Policy Assessment

Deputy For Natural Resources Development Technology
Deputy For Agroindustrial Technology And Biotechnology
Deputy For Information, Energy, And Material Technology
Deputy For Design And Engineering Industrial Technology
Government Institution,
coordinated by Ministry of Research, Technology and Higher Education
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CASCADING IMPACT, OUTCOME DAN OUTPUT BIDANG MATERIAL
 AKREDITASI
LABORATORIUM TEKNOLOGI
MATERIAL – PTM, TIEM, BPPT:
Laboratorium Teknologi Material - PTM
1. Laboratorium Pemrosesan Karet LP-1090-IDN

Akreditasi KAN
2. Laboratorium Karakterisasi Karet o No LP-1090-IDN
o Tanggal 22 Maret 2017
3. Laboratorium Sintesa Ceramic o Berlaku sampai 21 Maret 2021
o Laboratorium Pengujian SNI ISO/IEC
4. Laboratorium Sintesis Nanomaterial 17025:2008

5. Laboratorium Karakterisasi Material Penyesuaian ISO/IEC 17025:2017

o Formulir Pernyataan Kesesuaian
6. Laboratorium Karakterisasi Mekanis o Pemenuhan Persyaratan Akreditasi
Laboratorium dari SNI ISO/IEC 1725:2008 ke
7. Laboratorium Solar Cell ISO/IEC 17025:2017
o Telah dikirim ke KAN tanggal 6 Februari 2018
8. Laboratorium Sensor
9. Ruang Analis Kimia Bidang pengujian :
-Pengujian Fisika
10.Ruang Preparasi Kimia -Pengujian Kimia

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 Jumlah SDM : 55 orang
ASET PTM
Sumber Daya Manusia
S0 : S1 : S2 : S3 = 1 : 4 : 6 : 3
Jumlah SDM berdasarkan tingkat pendidikan

4 S0
Teknisi : 6 orang 13
S1
Tugas belajar : 11 orang (S2 : 5 orang, S3 : 6 orang) 15
S2
S3
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Bidang Ilmu :
-Materials Engineering
-Metallurgy and Material Engineering
-Chemical Engineering Peta SDM Berdasarkan Umur
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-Electrical Engineering 18
18

-Structure Engineering 16 15
14 12
-Industrial Engineering 12
10
-Materials Science Umur
8 6
-Chemistry 6 4
4
-Physics 2
0
-Management 21-30 31-40 41-50 51-60 >60
-etc
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 Alat PTM yang sudah terakreditasi KAN
• Pengujian Mekanis
- Universal Testing Machine 250 kN
- Microhardness Tester
LP-1090-IDN
• Karakterisasi Material
- FTIR
- TGA
- Spektrometer
• Pengujian Karet
- Mooney Viscometer
- Carbon Black Dispersion
- Rheometer
- Hardness Shore A
- Universal Testing Machine 2 kN
 ASET PTM
Sumber Daya Fasilitas
1 2 3 4 5

ALAT PENGUJIAN:
1. Universal Testing Machine 2kN
2. Universal Testing Machine 250kN
3. Dynamic Mechanical Analysis (DMA)
4. Hardness Shore A
5. Microhardness Vickers
6. Rebound Resilience Tester 6 7 8 9 10
7. DIN Abrasion Tester
8. Carbon Black Dispersion Tester
9. TGA-DTA-DSC
10. Spektrometer (OES)
11. Mooney Viscometer 12
11 13 15 16
12. Moving Die Rheometer
13. Compression Set
14. Nano DS 17
15. Mikroskop metalurgi
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16. Mikroskop polarisasi
17. BET (Brunaeur-Emmet-Teller)
18. FTIR (Fourier Transform Infra Red)
19. EIS (Electrochemical Impedance
Spectroscopy)
20. Density Balance 18 19

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 ASET PTM
Sumber Daya Fasilitas
1 2 3 4 5

ALAT PROSES DAN PREPARASI:

1. Kneader
2. Open mill
3. Hot press
6 7 8 9 10
4. Geer oven
5. Memmert oven
6. Grinder/polisher
7. Ball mill
8. Automatic abrasive cutting machine
9. Tube furnace 11
10. Alat potong sampel rheometer
11. DSS Furnace 12
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12. Alat potong sampel mooney
viscometer 13
13. Alat potong karet
14. Alat kompaksi
15. Extruder
16. Refrigerated high speed centrifuge
17. Furnace (820, 1300, 1250, 1750 °C) 15
18. Induction furnace
19. Alat potong spesimen uji karet
20. Mesin bubut

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 Pelayanan Teknologi – Jasa Pengujian
No Pengujian Fisika No Pengujian Kimia
1 Kekuatan abrasi Abrasion Tester 1 Densitas Density Balance

2 Uji tarik (tensile test) 2 Uji komposisi dengan spektra IR FTIR

3 Uji sobek (tear test) 3 Uji termal pada material TGA-DTA-DSC

Universal Testing Machine 2kN
4 Uji tekan (compression test) 4 Uji komposisi kimia logam Spektrometer (OES)

5 Peel test/adhesion 5 Uji korosi EIS

6 Uji tarik (tensile test) 6 Rheology (uji karakteristik vulkanisat karet) Rheometer

7 Uji tekan (compression test) Universal Testing Machine 250kN 7 Uji viskositas karet Mooney Viscometer

8 Peel test/adhesion

9 Kekerasan shore A Hardness Shore A

10 Kekerasan vickers Microhardness Vickers

Uji sifat mekanis dan viskoelastis (tension, shear,

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compression, bending) DMA
Variasi Pengujian dapat
12 Transition glass polimer pada suhu rendah diperluas
13 Particle size distribution Nano DS

14 High surface area BET

15 Pengamatan struktur mikro Mikroskop metalurgi

16 Uji pantul Rebound Resilience Tester

17 Level sebaran carbon black Carbon Black Dispersion Tester

18 Uji pemampatan Compression Set

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SARANA FASILITAS LABORATORIUM BTP untuk
Menunjang Industri Komponen Pesawat di Indonesia
 PENGUJIAN UMUM
• Material testing • Performance testing
– Material Identification o Vibration Test
– Element analysis o Pull-Push Test
– Chemical properties o Weigh drop
– Mechanical properties o Instalation & Removing test
– Thermal properties
• Acc Weathering Test
– Electrical properties
• Thermal shock, Heat Cycle
• Failure Analysis
• UV, Xenon Test
– Jug reduction
 LAYANAN PENGUJIAN BTP
• Hardness Measurement Test
• Accelerated Weather (Light) Resistance Test : Xenon Arc
• Heat Aging Test
• Adhesion Property Test
• Heat Deformation Temperature
• Bending Test • Heat Resistance Test
• Car Wash Test • Heat Shrinkage Measurement Test
• Charpy Impact Strength • Humidity Resistance Test
• Chemical Resistance Test • Impact Resistance Test
• Critical Heat resist. Test • Impact Test
• Density Test • Inorganic Content Measurement Test
• Determination of Water Absorption • Low temp. test
• Melt Mass-Flow Rate (MFR)and the Melt Volume-Flow
• Electro-Plated Surface Adhesion Strength Measurement Test Rate (MVR)
• Evaluation of the Test Result • Molding Shrinkage Measurement Test
• Flammability Test • Oil Immersion Test
• Fluid Resistance Test • Paint Film Adhesion Measurement Test

• Friction Color Fading Test • Permeability Test

• Glass Haziness Measurement Test • Preparation of Test Specimens by Molding

 LAYANAN PENGUJIAN BTP
• Resonance point detection
• Resonance vibration durability •Vicat Softening Point Measurement Test
• Scratch Resistance Test •Water Absorption Measurement Test
• Specific Gravity Measurement •Water Content Measurement Test
• Staining Test
•Water Resistance Test
• Stickiness Test
• Strength (Resistance) Test •Weather Resistance & Light Fastness Tests

• Tear Test •Wet Heat Aging Test

• Temperature and Humidity Cycle Test •Abrasion Test
• Temperature of Deflection under Load
•Peeling Test
• Temperature Resistance Test
•Plasticizer Migration Test
• Test Atmosphere
• Thermal cycle test •Surface Rubbing Resistance Test
• Transparency Measurement Test
CONTOH ALAT PENGUJIAN BTP
 UNIVERSAL TESTING MACHINE (UTM)
Pengujian Mekanik Polimer – Tensile, Flexural, Compression, Peeling, dlsb –
dilengkapi dengan climatic chamber untuk temperatur tinggi dan rendah < 0oC
 ALAT UJI IMPACT
Pengujian polimer akibat beban
kejut

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Durometer Hardness

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Ball Indentation Hardness

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Rockwell Hardness

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 Brittleness Temperature
“Temperature dimana material polimer mulai brittle”
Standard Pengujian :
• ASTM D746
• ISO 812
• JIS K 6261
Range Temperature
• -70°C to +20°C
• Media Pendingin berupa Dry ES / alcohol
• Waktu pengkondisian tiap temperature 3 menit
 Ozone Cracking Resistance
Ketahanan material polimer terhadap lingkungan ozone (O3)
 Compression Set
Untuk Mengukur regangan sisa dengan adanya tekanan dan
pemanasan khususnya untuk vulcanized rubber
• JIS K 6262
• ASTM D395
• ISO 815
 Flammability
Vertical Burning Test -
Horizontal Burning Test - “Metoda UL-94”
“Metoda ASTM D635 / UL-94 (HB)”
Flammability

Horizontal Burning Test

“Metoda ISO 3795 / FMVSS 302”
Thermal Resistance
Walk in Chamber
Specification
– Inside dimension : 5000 x 3500 x
3500 mm
– Temp range : (-40) - 95°C
– Humidity range : 15 - 95%

Test application
• High/low temperature resistance
test
• Thermal cycle test
Vibration Shaker with Chamber
Specification of Vibration Shaker
– Max payload : 610 kg
– Max Acceleration :
• Sine : 79 G
• Random : 50 G
• Shock : 158 G
– Frequency range : 5 – 3000 Hz

Specification of Chamber
– Inside dimension : 700 X 700 X 700 mm
– Temp range : (-75) - 180°C
– Humidity range : 15 - 95%
Vibration Shaker with Chamber
Test application
• Durability test at low or high
temperature
Hydrostatic Test
Specification
– Chamber dimension : 1920 X 860 X
1470 mm
– Temp range : 20 - 80°C
– Pressure range : 0 – 160 Bar

Test application
• Hydrostatic test
• Bursting test
 Accelerated Weathering
(Xenon Weather-o-Meter)
Specification
– Controlled temp, humidity,
irradiance, and water spray

Test application
– Light fastness test
– Accelerated weathering test
Ozone Cracking Tester
Specification
– Inside dimension : 500 x 500 x 500 mm
– Temp range : room temp - 70°C
– O3 density : Low density of 20 ~200
pphm
– Tensile stress : Static tensile stress with
strain of 0 - 100 %
– Rack rotation : Rotation speed of 2 rpm
– Standard : JIS-K6259(Core) & ISO-1431

Test application
• Ozone resistance test
 Alat Weathering-Xenon Arc
Pengujian Pelapukan (Aging)
dengan simulasi cuaca / cahaya matahari
 Alat Weathering-Fluorescent UV (QUV)

Pengujian Pelapukan
dengan simulasi cuaca /
sinar UV
 ALAT EXTRUDER (skema)
Pembuatan Kompon/Formulasi

Fig 1.11 buku biru ekstrusi

Screw bisa
dikombinasikan
ALAT INJECTION MOLDING (skema)
Pembuatan Spesimen Uji

MOLD
Fourier Transform Infra Red
Spectroscopy – Identifikasi material
polimer

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Thermogravimetry Analyzer (TGA)
Analisa komposisi material polimer
Peralatan terdiri dari:

• Thermobalance
• Sumber panas yang dapat diprogram
(memberikan kenaikan T secara linier)
• Thermoelement (sangat dekat terhadap
sampel)
• Alat Perekam
 Differential Scanning Calorimeter (DSC) (skema)
Analisa temperatur Transisi Polimer
Sample Reference

sensor

Heat flow in FRS5 sensor Heating

block
 Studi Kasus
Retread Ban Pesawat di PTM

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 Latar Belakang / Urgensi (1)
• Luas perkebunan karet Indonesia merupakan No. 1 di dunia (3,4 juta ha)
• Produktifitas lahan (994 kg/ha/tahun) masih di bawah Malaysia (1430
kg/ha/tahun) dan Thailand (1690 kg/ha/tahun)  menunjukan tingkat
produktifitas karet Indonesia masih harus ditingkatkan.
• Faktor penyebab:
kebun karet milik petani belum ditanami dengan klon unggul
teknik penyadapan yang tidak sesuai.
• Peningkatan produktivitas  penurunan biaya produksi dan
peningkatan pendapatan petani karet.

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 Latar Belakang / Urgensi (2)
• Masih kurangnya aktifitas industri hilir dalam
memberikan nilai tambah karet  Hanya sekitar 15%
dari produksi hulu dikonsumsi oleh industri hilir di
dalam negeri, sementara sisanya 85% dari karet alam
diekspor.
• Diperlukan suatu upaya terpadu dalam pengembangan
dan pelayanan teknologi, informasi, sertifikasi di bidang
karet, termasuk perumusan teknologi, inovasi dan
transfer teknologi.
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 Kebutuhan Ban Pesawat (1)
• Kasus Boeing 737-800/900
• Penggantian tiap 180-200 Flight Cycle
• 1 pesawat 4 buah, setiap hari 6 Flight Cycle
• Ada 100 pesawat  1 bulan 400 ban, setahun 4800 ban
Kebutuhan Ban Pesawat (2)

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Parameter
 Kekerasan : 60-65 Shore A
 Tensile Strength : >20 MPa
 Elongation at Break : 500 % max
 Abrasion resistance : >100 % ARI
 Compression set Loss : 20 % max
 Rebound Resilience : 45-70 %
 Aging Loss (H, TS, Abrasion, Rebound, Compression)
at 70⁰C, 48 jam : 20% max
 Prototipe Produk Hilir Karet

Target formula kompon

Formulasi dengan Open Mill

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 Formulasi dan Pengujian
Komponen
FN100C FN100C FN100C FN100C FN95C2 FN85C2 FN95C3 FN85C3 FN95C2 FN95C3 FN85C2 FN85C3
2050 3450 2030 3430 050 050 450 450 030 430 030 430
Natural 100 100 100 100 95 85 95 85 95 95 85 85
Rubber
Synthetic - - - - 5 15 5 15 5 5 15 15
Rubber
Homogenizer 3 3 3 3 3 3 3 3 3 3 3 3

Activator 8 8 8 8 8 8 8 8 8 8 8 8
CB1 50 - 30 - 50 50 - - 30 - 30 -
CB2 - 50 - 30 - - 50 50 - 30 - 30
Silica - - 20 20 - - - - - - - -
Coupling agent - - 2.5 2.5 - - - - - - - -

Antidegradant 2 2 2 2 2 2 2 2 2 2 2 2

Antioxidant 3 3 3 3 3 3 3 3 3 3 3 3
Antiozonant 3 3 3 3 3 3 3 3 3 3 3 3
Processing oil 6 6 6 6 6 6 6 6 6 6 6 6

Accelerator 3 3 3 3 3 3 3 3 3 3 3 3

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 Formulasi dan Pengujian

Sifat Mekanik Target FN100 FN100 FN100 FN100 FN95C2 FN85C2 FN95C3 FN85C3 FN95C2 FN95C3 FN85C2 FN85C3
C2050 C3450 C2030 C3430 050 050 450 450 030 430 030 430
Hardness Shore A 60 – 70 62.83 64.92 63.27 61.75 63.17 64.25 64.58 66.33 63.75 63.92 61.16 64.5
Rebound 45 – 55% 46.25 48.43 46.12 47.53 50.05 49.95 50.32 50.23 45.8 43.57 48.87 44.92
Resilience
Compression Set 15 – 35% 35.62 33.77 55.20 55.86 29.00 28.77 35.76 31.83 52.55 51.98 51.11 49.66
Abrasion ≥ 120% 87.36 99.58 93.81 85.49 113.23 124.86 102.29 108.93 83.5 85.03 82.36 85.61
Resistance ARI
Tensile Strenth at ≥ 20 MPa 22.5 21.4 22.1 21.6 22.7 21.6 21.2 19.6 22.0 19.3 21.0 19.1
Break
Tear Strength 200 – 300 340 321.2 352.1 334.2 326.8 278.1 259.9 279.1 321.5 308.3 273.1 248.7
N

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 Pembuatan KOMPON

Pembuatan Ban Vulkanisir

Spesimen uji abrasi Potongan untuk reverse

engineering ban pesawat

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Pengukuran dimensi ban pesawat

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Pengukuran dimensi ban pesawat

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 MOLDING
Tire Molding
Take measurement from
new tire for size and
profile

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 MOLDING
Tire Molding
Molding
profile

Molding
jacket

Tire molding design

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 MOLDING
Tire Molding

Tire molding design

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Tire Molding

Tire mould after assembly

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TIRE RETREADING PROCESS

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 "retreading" refers to the methods of restoring a used
retreadable tire by renewing the tread alone or by renewing
the tread plus the reinforcing ply(s) or protector ply.

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Repairable Aircraft Tires

The following are acceptable when retreading aircraft tires:

• Tread area
The size of cuts and/or other tread injuries that can be repaired
during retreading is dependent on many factors, including the
injury’s length, depth and width as related to the tire size itself.
The number and size of a repairable injury is also dependent on
the retreader’s repair methods and validation.

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Repairable Aircraft Tires
• Bead area
Minor injuries to the bead area may be repaired provided the carcass plies are
not damaged.

• Inner liner
Inner liner surface damage may be repaired (bias tires). The size of a repairable
injury is dependent on the retreader’s repair methods as well as government
regulatory documentation.

• Sidewall rubber
Surface defects on large commercial tires may be repaired provided the repair is
at least 1 inch from the bead heel, and no greater than an area 1-1/2 inches (50
mm) by 4 inches (100 mm), and does not penetrate or damage the carcass ply.

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Retreading Process

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Final Inspection and NDI

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Receiving Inspection and NDI

Visual inspection and Non Destructive Inspection

to ensure tire condition

Visual Inspection

Shearography
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Buffing Process

Removal of old tread and prepare tire

surface for new tread

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Tread Building

Cushion gum application and new

tread building

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Vulcanizing

The green tire then going into

moulding

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 TREAD

Ban setelah diBuffing Produk Stelah Proes Retread

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Witness Proses Manufaktur Prototipe Retread Ban Pesawat (Team PTM, DKPPU, PT. GMF, PT. CAR)
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Walk in Chamber Prototipe Setelah keluar dari Chamber

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Witness oleh Tim DKPPU

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PROTOTIPING and TESTING PHASE
Tire Material Compound Selected Compound
Composition (Produce Compound (Record Composition, Process Compounding
(Reverse Engineering Combinations) physical properties, etc)
from original tire)

Record all information

Select ex Tire for Retreading Tire
of tire
Retread Shearograph (in Proper Mould with
(Manufurer, no of
(free from damage) selected compound)
retreaded etc)

Static and Dynamic Test Prototipe Tire

(Refer to TSO C62e)* Shearograph, Balancing Retreaded

Retread Tire Pass * Such as: Static Test (bursting test, bead seat pressure, air retention, extreme
TSO Requirement climate, tire dimension
-Dynamic Test : Dynamometer test per FAA TSO C62e or ISO 3324-2
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