Engineering Failure Analysis最新文献

{"title":"Failure analysis of TiNbCr Multi-Principal element Alloy: Temperature-Dependent oxidation and internal degradation in oxygen atmospheres","authors":"Isabela Dainezi ,&nbsp;Brian Gleeson ,&nbsp;Carlos Alberto Della Rovere","doi":"10.1016/j.engfailanal.2025.109573","DOIUrl":"10.1016/j.engfailanal.2025.109573","url":null,"abstract":"<div><div>This study presents a failure analysis of a TiNbCr multi-principal element (MPE) alloy, focusing on its temperature-dependent oxidation behavior and internal degradation mechanisms in oxygen atmospheres. Thermal gravimetric analysis (TGA) conducted at varying temperatures revealed distinct oxidation mechanism: at 700 °C, a dense oxide layer formed; at 800 °C, a complex mixture of Nb, Ti, and Cr oxides was observed; and at 900 and 1000 °C, an innermost Cr₂O₃-rich layer developed, imparting improved oxidation resistance. Despite these temperature-dependent variations, the scaling kinetics of the alloy remained linear, with extensive internal oxidation observed at all exposure temperatures. In contrast, alloy 188 exhibited parabolic scaling kinetics and lower mass gain per unit area, demonstrating better oxidation resistance. The persistent presence of an internal reaction zone (IRZ) suggests that the oxide scale fails to act as an effective diffusion barrier, promoting internal degradation and increasing the risk of structural failure in high-temperature applications. Moreover, a comparison with previous studies suggests that the presence of nitrogen accelerates oxidation kinetics while reducing IRZ depth, affecting long-term material stability. These findings provide critical insights into oxidation-induced failure mechanisms, aiding in the development and selection of high-temperature alloys for aerospace, energy, and structural applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109573"},"PeriodicalIF":4.4,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777270","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigations on fatigue cracks in an aircraft engine crankshaft","authors":"Hwanjeong Cho ,&nbsp;Kyung-Suk Sohn ,&nbsp;Hongchul Lee","doi":"10.1016/j.engfailanal.2025.109571","DOIUrl":"10.1016/j.engfailanal.2025.109571","url":null,"abstract":"<div><div>Internal combustion engines are widely used in small and light vehicles due to their efficient fuel consumption and compact design. However, their dynamic components are susceptible to various mechanical failures. The crankshaft is particularly prone to fatigue due to its intricate structure and the significant loads it must endure. Despite design efforts to minimize this issue, such failures still occur in modern engines. This paper presents a failure analysis of a trainer aircraft crankshaft following in-flight vibrations and flame-out that led to a crash. Macroscopic examination and fractographic evaluations identified the initial fracture at one of the crankwebs, characterized by well-delineated, single-origin beach marks. A secondary fracture was observed at a second crankweb, exhibiting features consistent with rapid, multi-origin fatigue crack growth under elevated stress levels. Additionally, the forward displacement at one of the journal bearings was identified as a critical contributing factor. This displacement caused significant damage to the journal bearing in question, including forward tip wear, which led to rubbing against the fillet radius of the crankweb where the initial fracture was discovered. This localized contact initiated cyclic thermal cracks on the fillet radius and they progressively evolved into surface wear, spalling, and pitting. These surface discontinuities acted as stress raisers and ultimately nucleated the fatigue crack at the aforementioned crankweb.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109571"},"PeriodicalIF":4.4,"publicationDate":"2025-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747257","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Creep and failure of 3D-printed polymers: Impact of infill patterns and densities on shear strain and strength","authors":"Mohamad Alagheband,&nbsp;Mohammadhossein Kosarimovahhed,&nbsp;Qian Zhang,&nbsp;Sungmoon Jung","doi":"10.1016/j.engfailanal.2025.109568","DOIUrl":"10.1016/j.engfailanal.2025.109568","url":null,"abstract":"<div><div>Unlike cast polymer, the creep of 3D-printed polymer is influenced by interlayer bonding where shear stress plays a critical role. This study explores how shear stress affects the bonding and fracture of individual layers in creep of 3D-printed Tough PLA by examining Honeycomb, Grid, and Line patterns at 40 % and 90 % densities. Tensile and creep tests were performed, and Digital Image Correlation was used to measure the strain field. The Line pattern had the highest normalized Ultimate Tensile Strength but poor creep resistance due to concentrated shear strain between layers, leading to early failure. Conversely, the Honeycomb pattern displayed better creep resistance and uniform shear strain distribution, especially at higher densities, suggesting improved inter-layer bonding. Failure mechanisms differed: the Line pattern had localized shear strain along filaments, weakening inter-layer bonds, while the Grid and Honeycomb patterns had more evenly distributed shear strains, with failure starting at stress-concentrated intersections. Higher densities generally increase creep resistance by enhancing internal support and reducing strain concentration, thus improving layer-to-layer adhesion. However, high-density (90 %) Honeycomb samples unexpectedly had strain concentrations due to slicing algorithm limitations, potentially compromising interlayer bonding. ANOVA confirmed that the infill pattern and stress level significantly affect creep behavior (p = 0.0045 and p = 0.0064, respectively), with the interaction between infill pattern and stress level also reaching significance (p = 0.0039). These findings highlight that while higher infill density generally improves long-term resistance, its benefits vary with infill geometry, indicating the importance of tailored design for load-specific applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109568"},"PeriodicalIF":4.4,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143769162","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Corrosion protective performance evaluation of structural aircraft coatings in cyclic salt spray, outdoor and In-Service environments","authors":"A.J. Cornet ,&nbsp;A.M. Homborg ,&nbsp;L.’t Hoen-Velterop ,&nbsp;J.M.C Mol","doi":"10.1016/j.engfailanal.2025.109566","DOIUrl":"10.1016/j.engfailanal.2025.109566","url":null,"abstract":"<div><div>Eliminating hexavalent chromium-based corrosion inhibitors from structural aircraft coatings remains a significant challenge, primarily due to the lack of reliable accelerated test methods. This study evaluates the performance of various structural aircraft coatings under different exposure conditions, i.e. outdoor exposure, cyclic salt spray testing and in-service conditions, supplemented by environmental sensors. Quarterly inspections and scanning electron microscopy were used to evaluate corrosion damage. The findings highlight a lack of correlation between accelerated testing and outdoor exposure testing, likely driven by disparities in salt deposition, UV-radiation, time of wetness and temperature cycling. Additionally, galvanic couples between skin and fasteners remain difficult to protect, with chromate-based systems offering limited inhibition and alternative systems struggling to protect such complex assemblies. However, in lap-joints, alternative coatings outperformed chromate-based counterparts, likely due to their polymer matrices providing improved barrier properties, hence limiting access of electrolyte to the coating-aluminium alloy interface.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109566"},"PeriodicalIF":4.4,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747258","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure analysis of transmission gear in aircraft opposed piston Diesel engine using FEM method","authors":"Paweł Magryta,&nbsp;Konrad Pietrykowski","doi":"10.1016/j.engfailanal.2025.109569","DOIUrl":"10.1016/j.engfailanal.2025.109569","url":null,"abstract":"<div><div>The paper presents a case study of the failure of components of a reciprocating Diesel engine that is planned for use in the aviation sector. The PZL-100 engine is being developed in cooperation with company WSK PZL Kalisz. The object of the study was the gear used to transmit the engine’s drive. The gears are designed to transmit moments from the two crank-piston shafts to the propeller shaft used to propel the aircraft. The damage to the gears occurred as a result of operating the engine under stationary conditions during brake testing. Visual inspection of the engine revealed traces of gear seizure on the propeller shaft. In order to analyse the resulting fault and prevent it from occurring in the future, simulation studies were performed using the finite element method FEM in Catia v5 software. For this purpose, the geometric model of the propeller shaft gear was reflected. The material properties and the appropriate density of the calculation grid were selected. Boundary conditions, i.e. part restraint and force conditions (obtained from previous calculations in MSC Adams software) were applied to the model thus prepared. Due to the damage that occurred, it was decided to perform calculations in two variants: during normal gear operation and during the conditions that caused the damage, i.e. the extreme case of locking the wheel hub on the propeller shaft. The results of the simulation studies were presented in the form of stress maps on the outer surfaces of the gear. The maximum stress values were obtained on the gear shoulders at the hub, i.e. where the shoulders cracked. The simulation studies conducted made it possible to identify and confirm the problem occurring during the operation of the drive unit. As a result, it was proposed to change the geometry of the gears by strengthening their shoulders.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109569"},"PeriodicalIF":4.4,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143760737","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Corrigendum to “Research on the relationship between thermal aging of lubricating grease outside the contact area of bearing rolling elements and bearing lubrication failure” [Eng. Fail. Anal. (2025) 109127]","authors":"Qilong Zhao ,&nbsp;Qin Zhao ,&nbsp;Enhui Zhang ,&nbsp;Cheng Jiang ,&nbsp;Yanan Wang ,&nbsp;Wenjing Lou ,&nbsp;Ruliang Zhang ,&nbsp;Xiaobo Wang","doi":"10.1016/j.engfailanal.2025.109561","DOIUrl":"10.1016/j.engfailanal.2025.109561","url":null,"abstract":"","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109561"},"PeriodicalIF":4.4,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143783959","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure response and beam effect of bolt reinforced layer: Numerical modelling using FDM-DEM coupling method","authors":"Henghong Yang,&nbsp;Mingnian Wang,&nbsp;Li Yu,&nbsp;Xiao Zhang,&nbsp;Zhilong Wang,&nbsp;Dagang Liu","doi":"10.1016/j.engfailanal.2025.109562","DOIUrl":"10.1016/j.engfailanal.2025.109562","url":null,"abstract":"<div><div>Bolts reinforcing surrounding rock is a common reinforcement method. In this paper, through finite-discrete element coupling numerical simulations and model tests, the beam effect within the bolt reinforcement layer (BRL) is visualized, and the failure response of the overall BRL is investigated. First, a finite-discrete element (FDM-DEM) coupled numerical model is developed to conduct loading failure tests on BRL. Second, model tests are conducted to validate the FDM-DEM numerical model, which exhibits concordance with the failure location, evolution process, failure load (<em>σ</em>_F), and ultimate load (<em>σ</em>_U) of experimental results observed in BRL. While BRL without bolt reinforcement (BRLW) presents a “fragmentation” failure, BRL exhibits a comprehensive deformation failure owing to the beam effect, characterized by minor rockfalls of the tunnel crown. Finally, a parameter analysis was conducted to investigate the impact of bolt length (<em>L</em>_b), bolt spacing (<em>θ</em>_s), and bolting range (<em>θ</em>_r) on the failure response and beam effect of BRL. The results suggest that the increase of <em>L</em>_b and <em>θ</em>_r and the decrease of <em>θ</em>_s will each strengthen the beam effect of BRL, consequently enhancing the <em>σ</em>_F and <em>σ</em>_U.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109562"},"PeriodicalIF":4.4,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739291","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A light deformable multi-scale defect detection model for irregular small defects with complex background","authors":"Jianguo Duan ,&nbsp;Bingzong Zhang ,&nbsp;Qinglei Zhang ,&nbsp;Jiyun Qin","doi":"10.1016/j.engfailanal.2025.109565","DOIUrl":"10.1016/j.engfailanal.2025.109565","url":null,"abstract":"<div><div>Surface defect detection is a crucial aspect of quality inspection in the industrial sector, hindered by the challenges of recognizing irregular small defects and dealing with complex background interference. To address these issues, we proposed a novel model called Deformable Efficient Multi-Scale Net for Small Defects (DSE-NET), which incorporates three innovative components: (1) The Inverted Residual Efficient Multi-Scale Attention (iREMA) alleviates complex background interference issues efficiently through regions of interest. (2) The Small Defect Feature Pyramid Network (SFPN) addresses the issue of small defects by progressively processing the added small target feature layer. (3) The Deformable Darknet mitigates irregular defect problems through deformable convolutions. Extensive ablation and comparative experiments were conducted on our self-built Micro Bearing Defect database(MB-DET), Northeastern University Detection (NEU-DET) database, and Peking University Printed Circuit Board Detection (PCB-DET) dataset. Compared to the baseline model, DSE-NET has increased the Mean Average Precision at IoU = 0.5 ([email protected]) accuracy by 2.9 % ∼ 5.2 % while only expanding the Floating Point Operations per Second (FLOPs) by 1.2G and the number of parameters by 0.3 M. The work has contributed various efficient components in the Artificial Intelligence field and effectively alleviated various thorny issues in industrial surface defect detection. In addition, we developed a surface defect detection system based on real industrial scenarios and implemented the mobile deployment of the detection model, which verified the competitiveness of DSE-Net real-time detection. The relevant model deployment method code is available: <span><span>https://github.com/17854222655/Mobile-Deployment.git</span><svg><path></path></svg></span>.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109565"},"PeriodicalIF":4.4,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747256","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Interference behavior analysis of parallel cracks on train brake disc using XFEM","authors":"Jiacheng Shen ,&nbsp;Chun Lu ,&nbsp;Jiahuan He ,&nbsp;Jiliang Mo ,&nbsp;Jie Zhao","doi":"10.1016/j.engfailanal.2025.109563","DOIUrl":"10.1016/j.engfailanal.2025.109563","url":null,"abstract":"<div><div>The brake disc plays a crucial role in ensuring the braking safety of trains. However, fatigue cracks often appear on the surface of brake discs, and interference occurs when multiple cracks are concentrated in a limited area. In order to investigate the interference behavior between parallel cracks on the train brake disc, the extended finite element method (XFEM) is adopted in this work. The J-integral, stress intensity factor, T-stress, and deflection angle are calculated to describe the interference behavior of parallel cracks. The results show that the interference behavior between parallel cracks can affect the propagation rate and propagation path of the crack. Furthermore, the interference behavior is closely related to the parallel cracks’ spacing and length ratio. Based on this research, the propagation mechanism of parallel cracks on train brake discs could be further understood.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109563"},"PeriodicalIF":4.4,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143760738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing the seismic resilience of the Batıayaz masonry bridge, aftermath of 2023 Kahramanmaraş earthquakes, using iron and FRP clamp-dowel connectors in the arch: Failure tests and numerical modelling","authors":"Murat Cavuslu,&nbsp;Tuna Ülger","doi":"10.1016/j.engfailanal.2025.109544","DOIUrl":"10.1016/j.engfailanal.2025.109544","url":null,"abstract":"<div><div>Historic bridges are invaluable cultural landmarks that embody the architectural and engineering achievements of past civilizations. Preserving these structures, which are often vulnerable to seismic activity, is essential to safeguarding cultural heritage for future generations. This study examines the Batıayaz Bridge, which sustained significant damage in the February 8, 2023, Kahramanmaraş earthquakes. Originally, iron connectors were used between stones in the arch section of the bridge. This research investigates the potential of using FRP (Fiber Reinforced Polymer) connectors as an alternative to iron for enhancing the seismic resilience of the arch. The bridge was reinforced with both FRP-metal clamps and dowel connectors, enabling a comparison of its seismic performance under each configuration. The connectors were carefully installed between stones with specialized adhesives and Khorasan mortar. Reinforced stone elements then underwent compressive and tensile testing, yielding essential data on the connectors’ normal and shear stiffness, as well as the mechanical properties of the Khorasan mortar. A three-dimensional model of the bridge was created in FLAC3D software using the finite difference method. Individual stone elements were modeled with brick and wedge components, incorporating experimentally derived stiffness values. The Mohr-Coulomb material model was applied to both the stone elements and the foundation soil, with non-reflecting boundary conditions set at the model’s edges. Ten different ground motion simulations were conducted to assess seismic behavior. The seismic analyses for the two models, with FRP and metal connectors in the arch, indicated that both types significantly improved the bridge’s seismic resistance. Results revealed that the use of FRP and iron mechanical connectors in the arch section substantially modified the bridge’s seismic response compared to the configuration without connectors. Besides, no major differences were observed between FRP and iron connectors in terms of enhancing seismic resilience of the bridge. The findings suggest that corrosion-resistant FRP connectors provide a durable alternative to metal connectors, which are prone to degradation over time. Thus, FRP connectors represent a promising option for the long-term seismic strengthening and restoration of historic bridges.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109544"},"PeriodicalIF":4.4,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747259","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}