Engineering Failure Analysis最新文献

{"title":"Stiffness degradation failure mechanisms and probabilistic fatigue life analysis of TA1 clinched joints","authors":"Yue Zhang ,&nbsp;Xian Wang ,&nbsp;Ruitao Peng ,&nbsp;Changyou Xu ,&nbsp;Tao Shi ,&nbsp;Kexi Chen","doi":"10.1016/j.engfailanal.2025.109812","DOIUrl":"10.1016/j.engfailanal.2025.109812","url":null,"abstract":"<div><div>Lightweight connections present a challenging task in engineering, requiring assurance of reliability, safety, and adaptability. Additionally, the fatigue failure behavior and lifespan distribution of the connection structure must be considered. Therefore, it is essential to develop fatigue life prediction models. This study aims to advance the application of clinched joint technology in practical engineering by conducting fatigue tests on TA1 titanium alloy clinched joints at different stress levels. An in-depth analysis of the relationship between joint displacement, stiffness, and failure behavior revealed the fatigue failure mechanisms of the joint. Probability fatigue life curves were constructed based on four statistical models, and their performance was evaluated. The results show that the primary failure mode of TA1 titanium alloy clinched joints is fracture of the lower plate. As the number of cycles increased, both the failure displacement and extent of damage grew. Stiffness degradation curves show three different stages of fatigue failure and their failure mechanisms are analyzed. Furthermore, it is recommended to use the Gumbel model for fatigue life design, as it provides sufficient constraints on fatigue data with small sample sizes, making it well-suited for practical engineering applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109812"},"PeriodicalIF":4.4,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144331249","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":"Structural integrity and failure mechanisms of thermoplastic composite pipes for offshore applications: Insights from compressive and flexural testing","authors":"Obinna Okolie ,&nbsp;Nadimul Haque Faisal ,&nbsp;Harvey Jamieson ,&nbsp;Arindam Mukherji ,&nbsp;James Njuguna","doi":"10.1016/j.engfailanal.2025.109775","DOIUrl":"10.1016/j.engfailanal.2025.109775","url":null,"abstract":"<div><div>This research investigates the structural integrity and mechanical behaviour of a thermoplastic composite pipe (TCP) that is particularly used in the offshore energy industry. The TCP offers enhanced strength and high strength-to-weight ratio ideal for applications subject to varying loading conditions. Despite its structural benefits, the composite pipe is susceptible to delamination and other damage modes that compromise its performance. This study addresses the limited research on thermoplastic curved composite structures, especially in the context of debonding and stress distribution, by focusing on the behaviour of the TCP under compressive and flexural loading conditions. Non-destructive testing (NDT) methods, including X-ray computed tomography (XCT) and ultrasonic inspection, are employed to characterize internal damage mechanisms from these tests such as microcracking, fibre breakage, and matrix deformation at a microstructural level. Flexural testing indicates that failure initiates through tensile cracks in the outer layers, while compression testing reveals progressive damage through delamination, matrix degradation, and fibre buckling. The pipe stiffness and elastic modulus were ascertained to be 2184.2 MPa and 13.18GPa respectively. Microstructural analyses of compressive failure further reveal the complex failure pathways. This shows that matrix cracking and delamination are primary failure mechanisms driven by the polymer matrix’s limited fracture toughness and the complex stress interactions within the laminate. Delamination and matrix cracking are localized yet progressive, exacerbating the fibre to matrix separation which impact load-bearing capacity of the pipe. These findings underscore the importance of optimizing fibre orientation, matrix-fibre adhesion, and layer configuration to enhance structural toughness. This comprehensive evaluation of mechanical performance and failure mechanisms provides valuable insights for optimizing the manufacturing processes of TCP, aiming to improve durability, reduce material waste, and enhance long-term reliability in demanding service environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109775"},"PeriodicalIF":4.4,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144331330","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":"Content dependence of CO2 effect on the hydrogen embrittlement sensitivity of P110 steel for underground hydrogen storage: Experiments and DFT calculations","authors":"Shuanghe Chi ,&nbsp;Wei Gao ,&nbsp;Juan Shang ,&nbsp;Zhengli Hua ,&nbsp;Songrui Guo ,&nbsp;Chengpu Li","doi":"10.1016/j.engfailanal.2025.109808","DOIUrl":"10.1016/j.engfailanal.2025.109808","url":null,"abstract":"<div><div>The use of underground hydrogen storage enables large-scale and cost-effective storage of hydrogen. However, the presence of carbon dioxide (CO₂) in underground hydrogen reservoirs can influence the interaction between hydrogen and the tubing materials. This study investigated the effects of varying CO₂ concentrations on the hydrogen-assisted cracking in P110 steel by a combined study of fatigue crack growth rate (FCGR) experiments and density functional theory (DFT) calculations. Experimental results indicated that the presence of CO₂ accelerates the FCGR compared to pure hydrogen. As the concentration of CO₂ increased, the FCGR initially rose and then declined, peaking in 0.008 MPa CO₂ + 7.992 MPa H₂ (0.1 vol% CO₂ + H₂). Additionally, the presence of CO₂ promoted the emergence of the critical stress intensity factor for hydrogen-accelerated fatigue crack growth, bringing the turning point forward from 27 MPa·m^1/2 to approximately 17 MPa·m^1/2. DFT calculations elucidated that the activation energy for hydrogen dissolution first decreased and then increased as the partial pressure of CO₂ in the hydrogen environment rose. This suggested that the ease of hydrogen permeation into the steel surface initially decreased and then increased, in alignment with the experimental findings.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109808"},"PeriodicalIF":4.4,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144279176","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":"Study on the corrosion failure mechanism of X80 pipeline steel by chloride ion at different concentrations","authors":"Haoping Peng ,&nbsp;Wentao Lyu ,&nbsp;Changjun Wu ,&nbsp;Jianhua Wang ,&nbsp;Xuping Su ,&nbsp;Yonggang Zhao ,&nbsp;Shouwu Xu ,&nbsp;Zhiwei Li","doi":"10.1016/j.engfailanal.2025.109784","DOIUrl":"10.1016/j.engfailanal.2025.109784","url":null,"abstract":"<div><div>In this study, the stress corrosion cracking (SCC) behavior, electrochemical behavior and crack extension mechanism of X80 pipeline steel under different chloride ion concentrations were investigated. Slow strain rate tensile tests (SSRT), electrochemical tests and corrosion immersion tests were carried out on X80 pipeline steel using NaCl solution with concentrations of 1.75(±0.05) wt%, 3.50(±0.03) wt% and 5.25(±0.05) wt% as the test environment. The results showed that the yield strength of X80 steel decreased from 592 MPa to 560 MPa, the tensile strength from 668 MPa to 640 MPa, and the uniform elongation (UE) and elongation after fracture (EA) decreased from 6.22 % to 5.05 % and 9.2 % to 8.81 %, respectively, with the increase of chloride concentration. At the same time, the corrosion resistance of the steel decreased, the Tafel anode slope decreased by 293 %, the Fe²⁺ content in the corrosion product film increased, the self-corrosion current density increased, and the charge transfer resistance (Rct) decreased. Under the coordinated action of stress and chloride ions, the corrosion product film is destroyed, the ferrite is deformed, and the ferrite site becomes a source of pitting corrosion. Stress corrosion cracking is increased and extended here.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109784"},"PeriodicalIF":4.4,"publicationDate":"2025-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144312634","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":"Fluid-solid coupling large deformation failure analysis of bucket foundations in saturated clay","authors":"Hailei Kou,&nbsp;Xixin Zhang,&nbsp;Jiaming Huang","doi":"10.1016/j.engfailanal.2025.109807","DOIUrl":"10.1016/j.engfailanal.2025.109807","url":null,"abstract":"<div><div>The suction bucket foundation, utilized as the structural foundation for offshore wind turbines, generates pore pressure accumulation and reduces effective stress and eventually leads to failure through fluid–solid coupling during installation. To accurately predict changes in the load-bearing capacity of the suction bucket foundation during installation, a numerical simulation method for large deformation in fluid–structure coupling of saturated clay is proposed. The approach utilizes ABAQUS with its secondary development module, integrating the RTISS calculation method, the modified Cambridge soil model, and Biot consolidation theory. The accuracy of the RITSS large deformation finite element method for analyzing the penetration problems in saturated clay was validated through simulations of the cone penetration test (CPT). A numerical model was developed to analyze fluid–solid coupling in the suction bucket foundation during penetration and to assess the bearing capacity stability throughout installation. The results indicate that the normalized penetration resistance of a bucket foundation in Malaysian kaolin clay is 6.53. Within the initial 10 days, excess pore water pressure at the base of the bucket foundation decreased by 28 %, with the coefficient (Tc50) for 50 % maximum pore pressure dissipation time measured at 0.022. The proposed numerical simulation method for pore pressure dissipation was validated, providing valuable insights into addressing fluid–solid coupling in large deformation simulations of saturated cohesive soil.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109807"},"PeriodicalIF":4.4,"publicationDate":"2025-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144306747","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":"Damage mechanism on superalloy surface of coated gas turbine vanes after long-term service","authors":"Yang Chen ,&nbsp;Zhihao Yao ,&nbsp;Hongying Wang ,&nbsp;Jianxin Dong ,&nbsp;Jialin Peng ,&nbsp;Mo Ren ,&nbsp;Huanyu Yang ,&nbsp;Liuxi Leng","doi":"10.1016/j.engfailanal.2025.109797","DOIUrl":"10.1016/j.engfailanal.2025.109797","url":null,"abstract":"<div><div>This study explored the damage mechanisms of coated gas turbine vanes after long-term service. The diffusion processes at the coating/substrate interface led to two significant microstructural degradation. The surface degradation mechanism under service conditions differed from that in isothermal exposure tests. This phenomenon was attributed to the diffusion of Al before the coating spallation, resulting in local high Al content on the alloy surface and the formation of AlN subsequently. Microstructural reconstruction and recrystallization at crack root led to the smaller effective load-bearing area, while coating damage accumulated at trailing edge, accelerating the local failure. It will provide theoretical support for long-term safe service of gas turbine.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109797"},"PeriodicalIF":4.4,"publicationDate":"2025-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144271608","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":"Root cause analysis and damage mechanisms of radiant tube failure in the atmospheric distillation unit of an oil refinery","authors":"M.J. Hadianfard,&nbsp;H. Hassani Saleh","doi":"10.1016/j.engfailanal.2025.109804","DOIUrl":"10.1016/j.engfailanal.2025.109804","url":null,"abstract":"<div><div>This study investigates the root causes of the failure of a radiant tube in the atmospheric furnace of a distillation unit of a refinery. The tube’s failure resulted in crude oil leakage and significant damage. The research involved collecting data, reviewing records, measuring the remaining wall thickness at various points, and conducting detailed visual and microscopic examinations of the damaged tube. The crack path and its edges were analyzed using microscopy. For comparison, chemical composition analyses were performed on both the failed tube and an unused tube of the same material. Metallographic microstructure examinations were conducted using a Scanning Electron Microscope (SEM) equipped with Energy Dispersive Spectroscopy (EDS). Surface corrosion was visually inspected and analyzed with SEM and EDS, while corrosion products were identified using X-ray diffraction (XRD). Hardness measurements were taken at different points, and tensile tests were conducted to compare the mechanical properties of the failed and unused tubes. The results indicated that localized temperature increases occurred due to the impingement of flames or combustion products on the tube’s surface. Additionally, heat transfer was reduced because of coke deposition inside the tube. External corrosion mechanisms, such as scaling and fuel ash corrosion, significantly decreased the tube’s thickness. Observations included carburization, the formation of continuous networks of carbide, carbide growth, carbide spheroidization, and softening of the steel. The final failure happened under increased stress resulting from the reduced thickness, which was further aggravated by localized temperature rises. This ultimately led to creep-induced cracking at the grain boundaries, accompanied by minor plastic deformation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109804"},"PeriodicalIF":4.4,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144288807","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":"Fatigue failure analysis for marine propeller used titanium alloy under salty-water environment with the effect of corrosion durations","authors":"Wang Jinlong ,&nbsp;Peng Wenjie ,&nbsp;Liu Tianlong ,&nbsp;Wang Qingyuan ,&nbsp;Shi Zeyu ,&nbsp;Yu Gang","doi":"10.1016/j.engfailanal.2025.109805","DOIUrl":"10.1016/j.engfailanal.2025.109805","url":null,"abstract":"<div><div>The experimental investigation on marine propeller used titanium alloy under varying corrosion durations represents a significant research issue in both engineering practice and theoretical exploration. This study focuses on fatigue behavior and evaluation for marine propeller used TC4 titanium alloy through designed fatigue testing that corrosion duration exerts a non-negligible adverse impact on the failure mechanisms and life evaluation. The modified Murakami model incorporating coefficient <em>fr</em> demonstrated suitability for estimating the fatigue strength of pre-corroded TC4 with the combined influence of corrosion durations and surface scratches. Comparative analysis of fatigue life prediction models indicated that the modified Paris model provides stable life estimations with minimal error margins for TC4 under different corrosion durations. Microstructural characterization through scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) revealed a progressive grain coarsening phenomenon correlated with extended corrosion durations, accompanied by distinct cleavage and ductile fracture characteristics. EBSD imaging reveals coarse grain structures with significant strain concentration at low-angle grain boundary are detected, and the grain size significantly increases with the increases of pre-corrosion duration. These findings elucidate the mechanistic relationship between corrosion and fatigue failure in TC4, while the proposed modified models offer novel and essential tools for advancing fatigue research in marine equipment.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109805"},"PeriodicalIF":4.4,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144279177","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":"Experimental analysis on the influence of Rayleigh stepped pockets on the leakage and tribological characteristics of the segmented annular seal","authors":"Shuang Wang,&nbsp;Dan Sun,&nbsp;Zemin Yang,&nbsp;Huan Zhao","doi":"10.1016/j.engfailanal.2025.109806","DOIUrl":"10.1016/j.engfailanal.2025.109806","url":null,"abstract":"<div><div>In response to the problem of oil leakage caused by the wear of the main sealing surface due to the insufficient hydrodynamic pressure effect in the segmented annular seal applied in aero-engines, test pieces of segmented annular seal featuring Rayleigh stepped pockets were designed and processed. An experimental platform was constructed for the purpose of investigating the leakage and tribological characteristics of segmented annular seals. Experimental studies on the leakage and tribological characteristics of Rayleigh stepped pocket segmented annular seal (PSAS) and traditional segmented annular seal (TSAS) were carried out. The results indicate the increase in rotational speed, pressure difference and the decrease in inlet temperature leads to the increase of leakage. When subjected to the same conditions, TSAS main sealing surface displays typical abrasive and adhesive wear patterns, while, PSAS main sealing surface exhibits only adhesive wear. Rayleigh stepped pocket reduces the wear of the segmented annular seal. The increasing rotational speed, pressure difference and inlet temperature lead to the increase of casing temperature of the segmented annular seal. At 298 K and 633 K, compared with TSAS, the leakage of PSAS increases by an average of 10.59 %∼13.44 % and 9.83 %∼18.44 %, respectively, and the temperature of PSAS seal casing decreases by an average of 11.26 % ∼11.5 % and 8.45 % ∼8.75 %, respectively. Hydrodynamic pressure effect generated by the Rayleigh steeped pocket can increase the segmented annular seal equivalent clearance, reduce wear of the main sealing surface, and enhance the air-to-segment convection heat transfer.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109806"},"PeriodicalIF":4.4,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144331246","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 study on crankshaft failure in diesel engine of wheel loader","authors":"Karim Aliakbari","doi":"10.1016/j.engfailanal.2025.109793","DOIUrl":"10.1016/j.engfailanal.2025.109793","url":null,"abstract":"<div><div>Crankshafts are essential parts within internal combustion engines are prone to fatigue failure due to cyclic loading. This paper investigates the failure in a six-cylinder diesel engine crankshaft from a wheel loader, which exhibited an unusual fracture pattern. Unlike common failures where cracks initiate at the crankpin fillet and propagate toward the main journal, this crack originated at the fifth crankpin fillet and terminated at its center. Various analyses were conducted to determine the root cause of failure, including chemical composition testing, microstructural examination, mechanical testing, scanning electron microscopy of the fracture surface, and finite element analysis of stress distribution. The results indicated that a reduction in molybdenum content, low hardness, and inclusions MnS contributed to reduced fatigue resistance. Additionally, the structural stress assessment revealed that the greatest stress concentration occurred at the fillet of the crankpin, corresponding to the crack initiation site. Moreover, features such as beachmarks and striations on fracture surface indicate fatigue. This study provides new insights into influence of material properties and microstructure on heavy-duty crankshaft fatigue behavior, offering recommendations for improved design and manufacturing to enhance fatigue resistance and durability.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109793"},"PeriodicalIF":4.4,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144264000","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}