Engineering Failure Analysis最新文献

{"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":"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":"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}

{"title":"Research on the mechanical behavior of high-speed railway gear steel 20CrNi2Mo: Experimental and theoretical investigation","authors":"L. Ma,&nbsp;B.Y. Huang,&nbsp;F. Guo,&nbsp;X.M. Li,&nbsp;J.F. Cao,&nbsp;X.H. Zhang","doi":"10.1016/j.engfailanal.2025.109533","DOIUrl":"10.1016/j.engfailanal.2025.109533","url":null,"abstract":"<div><div>Gears are key components in the transmission system of high-speed railway trains, and their reliability is critical for the safe operation of trains. This study investigates the commonly used high-speed railway gear steel, 20CrNi2Mo, through systematic experimental and theoretical analysis. Based on the experimental results, it was found that the viscous effects of 20CrNi2Mo steel can be neglected, while the material exhibits significant changes in the hysteresis loop shape under cyclic loading. As the number of loading cycles increases, the hysteresis loop gradually becomes shorter and wider. Even when the applied stress is below the yield limit, initial deformation is primarily elastic, but plastic deformation and hysteresis loops develop over time. This phenomenon demonstrates a gradual reduction in the yield stress of the material under identical loading conditions, accompanied by a decline in elastic modulus. It further elucidates the evolution mechanism from elastic deformation to plastic failure during the fatigue process. Based on these experimental findings, the proposed constitutive model integrates improved fatigue damage evolution laws and coupling methods, incorporating elastic modulus and yield stress as damage factors. This model effectively explains material softening, hysteresis loop rotation, and widening observed during the fatigue process. Simulation results confirm that the model accurately captures the mechanical behavior at each stage of fatigue, with predicted life expectancy closely aligning with experimental outcomes. These findings provide a solid theoretical foundation and valuable reference for the failure analysis of gear transmission.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109533"},"PeriodicalIF":4.4,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739292","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 physics-informed framework for feature extraction and defect segmentation in pulsed infrared thermography","authors":"Luca Santoro,&nbsp;Raffaella Sesana","doi":"10.1016/j.engfailanal.2025.109542","DOIUrl":"10.1016/j.engfailanal.2025.109542","url":null,"abstract":"<div><div>This paper presents a robust and interpretable methodology for defect detection in active infrared thermography data applied to polyvinyl chloride (PVC) specimens. Our approach integrates a physics-based cooling model to describe the transient thermal response of each pixel, from which five primary temporal features are extracted via least-squares fitting. These features are then enriched with local spatial statistics through neighborhood-based computations, resulting in a 15-dimensional descriptor per pixel. The resulting feature set is used to train a random forest classifier, which achieves high overall accuracy (99.3%), competitive intersection-over-union (0.705), and an outstanding ROC AUC (0.998). In contrast to deep encoder–decoder networks that require extensive computational resources and large annotated datasets, the proposed pipeline offers enhanced interpretability and significantly reduced computational overhead. Comparative analysis with state-of-the-art deep learning models, such as those reported in Wei et al., (2023), demonstrates that our approach achieves similar performance while providing a transparent insight into the contribution of each feature. The proposed method is especially suitable for engineering failure analysis where model transparency, rapid evaluation, and integration into existing inspection protocols are critical. Future work will extend the framework to accommodate a broader range of defect types and material systems, aiming to further enhance industrial applicability and diagnostic reliability.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109542"},"PeriodicalIF":4.4,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143705939","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 a torsion spring: A microstructural and finite element assessment","authors":"Raj Shinde ,&nbsp;Mahesh N Pradhan ,&nbsp;Baidehish Sahoo ,&nbsp;Reliance Jain","doi":"10.1016/j.engfailanal.2025.109560","DOIUrl":"10.1016/j.engfailanal.2025.109560","url":null,"abstract":"<div><div>This study explores the premature failure of a torsion spring manufactured from cold-drawn stainless-steel wire. A comprehensive analysis was conducted which included microstructural examination through Optical microscope, FE-SEM, and XRD. The analysis of the fractured surface through Optical microscope &amp; FE-SEM revealed the inclusions, precipitates and porosity. The high dislocation density and residual stress were revealed by the XRD analysis. The mechanical characterization was evaluated through Vickers hardness testing where the fractured surface came up with higher values compared to that of the as-received one. Finite element assessment carried out to understand the stress distribution in the spring. The FEA simulation results corresponded well with the actual failure zones. In conclusion, the investigation indicated that the failure was due to material flaws and stress concentration folds in design.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109560"},"PeriodicalIF":4.4,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143715477","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}