Engineering Failure Analysis最新文献

{"title":"Design and validation of an in-situ hydrogen embrittlement system in a rotary bending fatigue testing machine","authors":"Jose Calaf-Chica,&nbsp;José E. Muñoz-Manero,&nbsp;María. J. García-Tárrago,&nbsp;Mónica Preciado-Calzada,&nbsp;Pedro M. Bravo-Díez","doi":"10.1016/j.engfailanal.2025.109882","DOIUrl":"10.1016/j.engfailanal.2025.109882","url":null,"abstract":"<div><div>Hydrogen is a promising clean energy source, but its integration brings challenges, notably hydrogen embrittlement (HE), which degrades materials used in hydrogen infrastructure. Metals, especially steel, are vulnerable, leading to reduced strength and safety risks. Testing methodologies, including in-situ and ex-situ methods, are crucial to understanding HE. In-situ methods simulate real-time exposure, whereas ex-situ methods focus on post-exposure effects. Rotary bending fatigue tests are particularly interesting as they are cost-effective fatigue machines. This study aims to design and implement an electrochemical cell for in-situ HE testing under cyclic loading in this particular fatigue machine.</div><div>The study focuses on adapting an electrochemical cell for a rotary bending fatigue machine, testing 42CrMo4 steel. Three key tasks were performed: (i) determining electrochemical parameters for inducing HE through Small Punch Tests (SPTs), (ii) evaluating an electrolyte jet system’s effectiveness, and (iii) designing and validating the electrochemical cell. Electrolytes tested included acid and alkaline solutions, and a novel jetting system was devised to ensure electrolyte coverage during high-speed rotation. The system’s electrical configuration and the cell’s structural adaptations for in-situ hydrogen charging were critical design elements.</div><div>The tests confirmed the system’s effectiveness in charging the specimen with hydrogen, as evidenced by fatigue life reduction and fracture surface analysis. Specimens precharged with hydrogen, specifically in acidic environments, displayed increased brittleness and premature failure, contrasting with the ductile behavior of non-embrittled specimens. This highlights the system’s potential for future studies on material resistance to hydrogen embrittlement under cyclic loads.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109882"},"PeriodicalIF":4.4,"publicationDate":"2025-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144665552","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":"Dynamic evolution mechanism of cracks in eccentric decoupled charge blasting under high in-situ stress in rock mass","authors":"Wantong Liu ,&nbsp;Yongsheng Jia ,&nbsp;Fang Yuan ,&nbsp;Nan Jiang ,&nbsp;Quanmin Xie ,&nbsp;Xin Liu","doi":"10.1016/j.engfailanal.2025.109909","DOIUrl":"10.1016/j.engfailanal.2025.109909","url":null,"abstract":"<div><div>As a core technology for deep rock mass excavation, the blasting performance of the drilling-and-blasting method is profoundly governed by the coupling effect between charge configuration and in-situ stress fields. However, existing literature has not fully elucidated the mechanism of eccentric decoupled charge (EDC) induced by gravitational forces during field charging operations, nor its coupling dynamics with in-situ stresses. This study first establishes a theoretical model of the coupled stress field through mechanistic analysis to decode the stress superposition principle. Laboratory single-hole blasting experiments are then conducted to validate the numerical model and calibration parameters. Using numerical simulations, crack propagation patterns are systematically investigated under both stress-free and in-situ stress conditions. Hough transform-based image processing techniques are employed to quantitatively analyze the influence of the radial decoupling coefficient (<em>M</em>) on blasting crack distributions in stress-free environments. Fractal dimension theory and fractal damage mechanics are integrated to characterize crack propagation in isotropic/anisotropic stress fields and quantify stress-induced rock damage. Results indicate that the frequency of crack initiation on the coupled side exceeds that on the decoupled side by 5.67%–36.82%. In-situ stress exerts bidirectional control over crack evolution: the maximum principal stress dictates the direction of crack extension while reducing fractal damage by 9.3%–12.5%. Notably, EDC significantly alters dynamic stress evolution, with the peak disparity between tensile and compressive hoop stresses identified as the critical factor driving divergent crack patterns. The research findings clarify the coupling mechanism between EDC and in-situ stress. When applied to blasting engineering in deep surrounding rock, this mechanism can significantly improve the semi-perforation rate and reduce overbreak. The study provides a theoretical basis and technical support for smooth blasting in deep surrounding rock engineering.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109909"},"PeriodicalIF":4.4,"publicationDate":"2025-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144662169","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":"Buckling failure mechanism of testing tubing string induced by expansion joint piston force in ultra-deep wells: experimental, numerical and design optimization approaches","authors":"Liangliang Ding ,&nbsp;Tao Liao ,&nbsp;Zhanghua Lian ,&nbsp;Qiang Zhang ,&nbsp;Qiaolei Sun ,&nbsp;Lang Wang ,&nbsp;Xiantao Dai","doi":"10.1016/j.engfailanal.2025.109907","DOIUrl":"10.1016/j.engfailanal.2025.109907","url":null,"abstract":"<div><div>The complex mechanical environment during ultra-deep well testing operations easily induces buckling failure of the tubing string near the expansion joint, posing significant risks to operational safety. To address this issue, this study established a coupled wellbore temperature–pressure field and tubing string mechanical behavior analysis model, revealing the generation mechanism of piston force loads under the partially stretched state of the expansion joint and their dominant role in tubing string buckling. A case study of an ultra-deep well was used to quantify the influence patterns of parameters such as wellhead pressure, pump pressure, and displacement on tubing string buckling risk. Additionally, a new expansion joint design was proposed. The results indicate that when the expansion joint is in a partially stretched state, an additional piston force load of up to 368.94 kN is generated on the inner and outer cylinders, which is the primary cause of tubing string buckling failure. To mitigate plastic deformation of the tubing string, increasing wellhead annular pressure, reducing pump pressure, enhancing displacement, and decreasing the installation depth of the expansion joint are effective measures. To resolve the issue of excessive piston force in conventional expansion joints, a dual-pressure chamber expansion joint was designed based on force equilibrium principles. Experimental verification demonstrated that this design reduces piston force loads by approximately 50%. This study provides theoretical foundations and technical solutions for the safety design and optimization of testing tubing string with expansion joint, offering critical insights for the development of ultra-deep oil and gas resources.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109907"},"PeriodicalIF":4.4,"publicationDate":"2025-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654577","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":"Understanding the directional deformation and failure characteristics of wire arc additively manufactured Ni-based superalloy using in-situ testing and DIC","authors":"Yoshit Tiwari ,&nbsp;Diya Mukherjee ,&nbsp;Sandip Haldar ,&nbsp;Himadri Roy ,&nbsp;Kaustav Barat ,&nbsp;Manidipto Mukherjee","doi":"10.1016/j.engfailanal.2025.109902","DOIUrl":"10.1016/j.engfailanal.2025.109902","url":null,"abstract":"<div><div>Ni-based superalloys produced by Wire Arc Additive Manufacturing (WAAM) develop pronounced columnar dendritic grains that extend in the build direction (BD) due to a steep thermal gradient acting opposite to BD, leading to anisotropic mechanical properties. While conventional tensile tests fail to resolve intrinsic crack-tip micro mechanisms, this study employs in-situ tensile testing and Digital Image Correlation (DIC) to investigate directional deformation and failure behaviour in WAAMed Inconel 625. Specimens extracted along and transverse to the BD exhibit distinct microstructural and mechanical responses. The vertical (BD) sample shows columnar dendrites with [001] texture, Nb/Mo segregation, and Laves phases (∼3.57 µm), resulting in lower yield strength (YS: 394 MPa) and ultimate tensile strength (UTS: 675 MPa) but 23 % higher elongation than the horizontal sample. In contrast, the horizontal sample exhibits 31 % higher YS (519 MPa) and 14 % higher UTS (772 MPa), attributed to increased strain hardening and a higher fraction of low-angle grain boundaries (LAGBs: 42 %). DIC reveals higher notch sensitivity in the horizontal sample, while the vertical sample demonstrates rapid strain hardening near yield (9931 MPa vs. 5627 MPa). These findings highlight the critical role of grain orientation and Laves phase distribution in governing anisotropy, providing actionable insights for designing WAAM components for multiaxial loading applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109902"},"PeriodicalIF":4.4,"publicationDate":"2025-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654575","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 structural strength of medium and low speed maglev vehicle levitation frame based on full-scale test bench","authors":"Yaqun Ma ,&nbsp;Weihua Ma ,&nbsp;Miao Li ,&nbsp;Qinghui Liu ,&nbsp;Shihui Luo ,&nbsp;Yu Wang ,&nbsp;Cheng Lei","doi":"10.1016/j.engfailanal.2025.109901","DOIUrl":"10.1016/j.engfailanal.2025.109901","url":null,"abstract":"<div><div>The structural strength of the levitation frame is crucial for the safe operation of medium and low speed maglev vehicle. This paper integrates theoretical calculations, dynamic simulations, and finite element analysis (FEA) to determine levitation frame boundary loads, identify weak points, and calculate cumulative damage. A full-scale strength test bench was constructed, and static and fatigue strengths were evaluated using the Fourth Strength Theory and a modified Goodman-Smith (GS) diagram, validated through fatigue tests and non-destructive testing. Results show that under emergency landing brake conditions, the peak stress at the parking brake skid is 67.22 MPa, below the material’s yield limit; high stresses are mainly concentrated in conditions with smaller load-bearing contact areas. Stress analysis indicates that stress amplitude and mean stress are distributed in the central region of the GS diagram, with stress amplitude having a significant impact, revealing the important influence of dynamic loads on fatigue strength. Good agreement is observed between critical areas and stress distributions from FEA and bench tests. Cumulative damage analysis shows higher damage in weld areas than in base material, with a maximum cumulative damage of 0.19 at the traction rod seat fillet weld. Non-destructive testing after fatigue tests found no cracks. These results validate the effectiveness and accuracy of the method presented in this study.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109901"},"PeriodicalIF":4.4,"publicationDate":"2025-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654576","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 novel TCD framework for fatigue lifetime prediction incorporating defect and stress concentration effects","authors":"Miaodong Zhao ,&nbsp;Dianyin Hu ,&nbsp;Jianxing Mao ,&nbsp;Jinchao Pan ,&nbsp;Tinglian Zhang ,&nbsp;Rongqiao Wang","doi":"10.1016/j.engfailanal.2025.109900","DOIUrl":"10.1016/j.engfailanal.2025.109900","url":null,"abstract":"<div><div>Defects in powder metallurgy (PM) superalloy tend to become a source of cracks under cyclic loading, reducing the fatigue lifetime of crack initiation and affecting the safety of aero-engines. The mechanism of crack initiation is affected by both the defect type and the gradient stress distribution, resulting in the large difference of fatigue lifetime. To study the relationship between the defect type at the crack source and the fatigue lifetime under the influence of stress concentrations, a series of fatigue experiments of notched round bar specimens were carried out. Then a modified theory of critical distance (TCD) on the basis of concern range of defect was proposed, which accommodates both surface defects and internal defects cracking mechanism. Compared to the experimental results, prediction results of fatigue lifetime fell within a scatter band of ±4. Finally, a concept of inclusion sensitive area (ISA) was proposed to quantify the area of stress concentration that was susceptible to cracking due to inclusion. It was validated by the fracture surface observation, where all inclusions on crack sources in the experiment were within the predicted region. This work will support lifetime prediction and defect detection strategies for aero-engine components.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109900"},"PeriodicalIF":4.4,"publicationDate":"2025-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144672533","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":"Highly energy absorption capability of biomimetic thin-walled structures inspired by woodpecker beak integrated with turtle shell curvature","authors":"Jingxuan Zhang ,&nbsp;Yuna Sang ,&nbsp;Yichen Zhou ,&nbsp;Chao Sui ,&nbsp;Yushun Zhao ,&nbsp;Chao Wang","doi":"10.1016/j.engfailanal.2025.109904","DOIUrl":"10.1016/j.engfailanal.2025.109904","url":null,"abstract":"<div><div>Energy absorbing structure is crucial for impact protection under complex loading conditions. This study proposes an efficient lightweight impact-protection structure with sinusoidal and circular thin-walled beams, inspired by the beaks of woodpeckers integrating with shells of turtles. The finite element simulations on compression and impact reveal that the structure undergoes progressive deformation as the amplitude increases. The analysis results show that both total energy absorption (<em>EA</em>) and specific energy absorption (<em>SEA</em>) are significantly influenced by the amplitude, with the maximum <em>SEA</em> reaching 6.75 J/g which is nearly 3 to 4 times higher than the conventional honeycomb structures. Additionally, the results also indicate that increasing the thickness of the structural walls can enhance the compression strength. However, this could lead to a higher total mass and reduced effective compression deformation, which in turn decreases <em>SEA</em>. This research offers a novel approach to designing lightweight protective structures for applications in energy absorption.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109904"},"PeriodicalIF":4.4,"publicationDate":"2025-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144672534","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":"Analysis of erosion characteristics of Al2O3-SiC-SiO2-C castable-poured in blast furnace hearth","authors":"Mingbo Song ,&nbsp;Yanbing Zong ,&nbsp;Cui Wang ,&nbsp;Jianliang Zhang ,&nbsp;Huangyu Shi ,&nbsp;Xiaoting Yang","doi":"10.1016/j.engfailanal.2025.109903","DOIUrl":"10.1016/j.engfailanal.2025.109903","url":null,"abstract":"<div><div>This paper investigates erosion behaviors of Al₂O₃-SiC-SiO₂-C (ASSC) castable refractory in a 2650 m³ blast furnace hearth. Post-service residual thickness measurements, conducted via 3D laser scanning and manual gauging across multiple hearth orientations with radial sampling at 8.7 m and 6.7 m elevations, revealed critical erosion zones at the “elephant foot” region (1.5–2 m below taphole centerline) and furnace bottom. Minimum residual thicknesses were recorded at 300 mm (sidewall) and 160 mm (bottom), with erosion rates reaching 81.99 % (314.6 mm/yr) and 84.00 % (168.0 mm/yr), respectively. The 3D erosion profile exhibited a distinctive “shallow pot-bottom” morphology, where measured thicknesses exceeded theoretical predictions by approximately 50 mm. Scanning Electron Microscopy-Energy Dispersive Spectroscopy (SEM-EDS) analysis elucidated erosion mechanisms: The taphole area exhibited tri-layered degradation from molten iron, slag, and harmful elemental penetration, while the elephant foot region showed predominant iron and elemental infiltration. Design recommendations include increasing ASSC layer thickness in taphole and elephant foot zones, along with thermocouple integration for real-time monitoring. Operational strategies to prolong refractory lifespan involve maintaining saturated carbon/silicon content in hot metal, controlling charge impurities, and implementing regular alkali removal protocols. These findings provide mechanistic insights for optimizing hearth design and operational practices in large-scale blast furnaces.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109903"},"PeriodicalIF":4.4,"publicationDate":"2025-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654616","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":"Seismic retrofitting of the historic Şirvani Mosque using fiber-reinforced polymer (FRP): A case study","authors":"Muneeb Jadallah ,&nbsp;Rami Alghamri ,&nbsp;Adem Doğangün","doi":"10.1016/j.engfailanal.2025.109898","DOIUrl":"10.1016/j.engfailanal.2025.109898","url":null,"abstract":"<div><div>This study investigates the seismic retrofitting of the historic masonry Şirvani Mosque using fiber-reinforced polymer (FRP). The mosque measures 22 m by 19 m with a height of 6 m and features a 35-meter-tall minaret that suffered severe damage during the February 26, 2023, earthquake in Turkey. Cracks developed in the arches, walls, and dome of the mosque, underscoring the urgent need for structural strengthening, particularly for the minaret, which ultimately collapsed.</div><div>To evaluate the mosque’s seismic behaviour, nonlinear time history analyses were carried out using the Extreme Loading for Structures (ELS) software. Initial simulations validated the mosque’s vulnerability, successfully reproducing the observed damage patterns and collapse of the minaret under strong ground motion. Following this, a retrofitting solution incorporating FRP was modelled within the same software environment. The analysis results showed that FRP retrofitting significantly improved the structural resilience of the minaret. The superior tensile properties of FRP effectively reduced displacements and stress concentrations during seismic loading, preventing collapse and ensuring the structural integrity of the minaret.</div><div>This retrofitting approach not only addresses existing damage but also enhances the long-term durability and seismic performance of the mosque. By combining advanced dynamic analysis techniques with modern strengthening materials, this study presents a robust framework for the preservation of historic structures. The Şirvani Mosque’s minaret case study highlights the potential of contemporary retrofitting methods to safeguard cultural heritage while improving seismic performance.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109898"},"PeriodicalIF":4.4,"publicationDate":"2025-07-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144634386","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 analysis and mechanism study of submersible electric pump made of high nickel austenitic cast iron","authors":"Zhang Zhaowei ,&nbsp;Li Bingjie","doi":"10.1016/j.engfailanal.2025.109895","DOIUrl":"10.1016/j.engfailanal.2025.109895","url":null,"abstract":"<div><div>Submersible electric pump plays a key role in the oil extraction, however, the failure of the impeller and guide vane often causes accidents, resulting in lower deliverability. In this study, the failure mechanism of high nickel alloy submersible electric pumps in the production wells of an oilfield in Bohai Sea was analyzed from the perspective of micro-materials science by carrying out tests such as macro-morphological analysis, optical microscope (OM), metallographic analysis, scanning electron microscope (SEM) and energy spectrum analysis (EDS), chemical composition analysis, and combining with the hydrodynamics and on-site working conditions. The results show that the spoon-like perforation of the guide vane is in horizontal alignment with the spoon-like perforation of casing. And plough-like microstructure is observed in the perforation position. Besides, a large number of white ceramic balls is discovered in the pump. Therefore, it is inferred that the failure mode of the pump is that the fluid carrying particles wear the guide vane and casing, resulting in perforation. The C-type graphite in the matrix of the guide vane is the essential reason of the erosion wear, which has a negative impact on the erosion resistance. The proportion of pearlite in the microstructure of the pump casing is relatively high, resulting in a decrease in the wear resistance of the matrix.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109895"},"PeriodicalIF":4.4,"publicationDate":"2025-07-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654578","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}