Investigation of a premature failure axle from a road-rail truck under rotary bending fatigue

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-02-28 DOI:10.1016/j.engfailanal.2025.109464

Pedro R. da Costa , V. Infante , M. Freitas

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引用次数: 0

Abstract

The present study provides a detailed analysis of an axle from a road-rail truck. The main objective of this work was to characterize a premature axle fracture failure in the context of ongoing derailment investigations. A comprehensive material and macro/micro analysis of the axle fracture was conducted which revealed that the premature failure resulted from rotary bending fatigue. The fatigue fracture occurred specifically in the braking system attachment zone. Microscopy and SEM analysis demonstrated that initiation occurred on the surface of the axle. A combination of critical factors resulted in imposing stress below the fatigue strength and leading to a premature failure of the axle. The determined critical factors were fretting damage, stress induced by tightening, and rotary bending. Through the combination of all identified influential variables, multiple crack initiation sites were detected across the braking system press-fitted regions. Following the forensic examination, a plan was proposed outlining the necessary actions, checks, and tests necessary to correct the existing failure through maintenance and/or establishing the time intervals between axle inspections. Corrective actions were recommended regarding the assembly and regular inspection of the braking system, focusing on the contact pressure region with the axle. The routine inspection should include a thorough examination of the fretting affected region for potential cracks and uneven damage utilizing visual amplifying means and ultrasonic testing.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.