Engineering Failure Analysis最新文献

{"title":"Failure analysis-based mass reduction of an aluminium alloy engine mounting bracket using Design of Experiments approach","authors":"","doi":"10.1016/j.engfailanal.2024.108927","DOIUrl":"10.1016/j.engfailanal.2024.108927","url":null,"abstract":"<div><div>In this study, mass reduction of an engine mounting bracket has been performed without changing the failure mode. Firstly, failure modes were determined experimentally using failure loads provided by the vehicle manufacturer. Then critical stress concentration areas and suitable mass reduction regions were determined by using Finite Element Analysis (FEA) for these load cases. A structural optimisation process was carried out using Design of Experiment-Response Surface Methodology (DOE-RSM) to minimise the mass while keeping the failure load as constant as possible. When the stress values obtained from the preliminary structure are compared with the values obtained from the optimised part, it was seen that this target has been mostly achieved. A total mass reduction of 4.31 % was achieved in the new part through failure mode analysis. Furthermore, it was found that a financial saving of 129,000 Euro could also be achieved.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142358301","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 remaining life prediction of high pressure turbine casing with unacceptable defects","authors":"","doi":"10.1016/j.engfailanal.2024.108930","DOIUrl":"10.1016/j.engfailanal.2024.108930","url":null,"abstract":"<div><div>Remaining life of a high-pressure turbine (HPT) casing of aircraft turbofan engine with cracks was determined. Cracks were detected during regular inspection and found out to be initiated by scratches made by non-skilled use of Electrical Discharge Machining (EDM). In total, 9 visible surface marks were made. Keeping in mind that this component is not repairable, and its replacement might be time-consuming and/or too expensive, it was essential to evaluate the remaining life and prevent failure if this component was to be used with cracks. Toward this aim, numerical methods had to be used, since testing of samples or component itself was not possible due to geometry restrictions. To get a reliable estimation of the remaining life, it was necessary to evaluate Paris coefficients C and m. Use of available data for fatigue crack growth was not an option, since coefficients are determined for virgin material and could not provide acceptable predictions for the used material. To overcome these difficulties, an innovative technique in two steps, based on finite element method, has been introduced. First step was to simulate fatigue crack growth. Then, response surface optimization (RSO) was used to obtain Paris’ coefficients that predict accurately the number of loading cycles to reach detected crack lengths, provided by the maintenance, repair, and operations (MRO) company’s workshop. Coefficients C and m, determined in this way, were then used to evaluate remaining life of the HPT casing and estimate the risk of its further use.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417997","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":"Prediction of fatigue life of a bolted joint in railway steel arch bridge using multiaxial fatigue criteria","authors":"","doi":"10.1016/j.engfailanal.2024.108908","DOIUrl":"10.1016/j.engfailanal.2024.108908","url":null,"abstract":"<div><div>Fatigue represents a critical condition for infrastructure subjected to repeated cyclic loads, such as steel railway bridges. The literature offers several methods to estimate fatigue life, consisting of three main phases: cycle counting, fatigue damage criterion, and damage accumulation criterion. Applying S–N curves might not be conservative in the case of railway bridges subjected to traffic because the stress-time history is complex and cannot be reduced to a sinusoidal history. Additionally, the presence of a multiaxial stress state must be considered. Therefore, this work compares eight multiaxial fatigue damage criteria for evaluating fatigue life in a scenario between high and low-cycle fatigue. Specifically, the authors considered four low-cycle fatigue criteria, namely Smith–Watson–Topper (SWT), Kandil, Brown and Miller (KBM), Glinka, Fatemi and Socie (FS), and four high-cycle fatigue criteria, Crossland, Basquin and the methods recommended by Eurocode 3 and British Standard. The rainflow counting method in ASTM E1049-85 (2011) and Miner’s rule for damage accumulation were used. The Polcevera railway steel bridge was selected as a case study. A 3D numerical model was developed for this purpose using Midas Civil software, taking into account the material non-linearity of the bridge’s elements. Once the area with the highest stress concentration was identified, a detailed analysis was conducted to estimate the stress and strain time histories induced by train traffic. A sensitivity analysis was conducted after critically comparing the eight methods for predicting fatigue life to assess the impact of traffic parameters, train velocity, axle load, and convoy length on fatigue life. It has been found that the criteria considering axial stress tend to overestimate the number of fatigue cycles to failure compared to the criteria, including the effect of shear stress components.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142420529","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":"Experimental and numerical studies on the collapse of Titanium alloy ring-stiffened cylinder","authors":"","doi":"10.1016/j.engfailanal.2024.108928","DOIUrl":"10.1016/j.engfailanal.2024.108928","url":null,"abstract":"<div><div>This paper investigates the collapse of ring-stiffened Titanium alloy cylinders used for subsea resource exploration under hydrostatic pressure through experimental and numerical methods. Extensive material tests were first conducted on Titanium alloy specimens to obtain the fundamental mechanical properties and variation characteristics. Then, a 4236 mm-long test cylinder was fabricated with an inner radius of 650 mm and a thickness (<em>t</em>_s) of 18.85 mm. The initial geometric imperfection was measured at evenly-spaced positions in the axial direction and 48 locations around the circumference by dial gauges. Afterward, the test cylinder was transferred into a custom hyperbaric pressure vessel and pressurized to collapse. As to the numerical analysis, a user-defined material subroutine implementing the incremental <em>J</em>₂ deformation theory was developed to predict plastic bifurcation pressure. Moreover, a nonlinear finite element (FE) model, which incorporated the measured geometric imperfection and material nonlinearity, was used to reproduce the experiment. The numerical results were found to exhibit reasonably good agreement with the test data. In addition, parametric studies were conducted regarding material properties, geometric parameters, and imperfection sizes on the load-carrying capacity of Titanium alloy ring-stiffened cylinders.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417812","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":"Very high-cycle fatigue behavior of steel in hydrogen environment: State of the art review and challenges","authors":"","doi":"10.1016/j.engfailanal.2024.108898","DOIUrl":"10.1016/j.engfailanal.2024.108898","url":null,"abstract":"<div><div>Global warming and extreme climate problems caused by the intensive exploitation of fossil fuels have become increasingly serious. With the urgent global demand for clean energy, green hydrogen energy has become one of the important directions for future energy transformation due to its zero carbon emissions and wide source. However, embrittlement occurs in almost all metals when exposed to hydrogen, which greatly hinders the development of the hydrogen energy industry. Furthermore, the key application terminals of hydrogen energy are found in engineering equipment for aerospace, civil engineering, transportation and other fields. These equipments must endure long life with high reliability operation requirements. Therefore, accurately evaluating their Very High Cycle Fatigue (VHCF) characteristics in a hydrogen environment is the key for the future advancement of the hydrogen energy industry. In this article, the latest related research on VHCF failure behavior and hydrogen embrittlement mechanisms are briefly reviewed. At the same time, this work focuses on the impact of hydrogen on VHCF behavior, with the aim to provide some guidance for the research on VHCF characteristics and the design of metal equipment in hydrogen environment. Finally, this review summarizes the current higher-level challenges of VHCF research in hydrogen environments and provides some potential tools that may further address these challenges.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142421073","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 hysteresis behavior of two kinds of reinforced CHS X-joints","authors":"","doi":"10.1016/j.engfailanal.2024.108919","DOIUrl":"10.1016/j.engfailanal.2024.108919","url":null,"abstract":"<div><div>Ultra-low cycle fatigue loading tests were conducted on two reinforced CHS X-joints (external stiffening rings and plates) and an unreinforced joint to analyze their post-yield failure modes, fracture mechanisms, and hysteretic properties. The findings indicate that these three joints exhibit varying failure modes post-yield: the unreinforced joints fail primarily due to chord fracture at the weld; the ring-reinforced joints initially see ring fracture, followed by chord crack at the weld; while the plate-reinforced joints initially fail from chord fracture and subsequently develop cracks at the plate-chord interface. The reinforced joints display plumper hysteretic loops and higher ultimate bearing capacities than the unreinforced joint. Compared to X-1, the tensile and compressive ultimate bearing capacities of RX-1 have increased significantly by 56.9 % and 74.1 %, respectively. In comparison, those of TX-1 have increased moderately by 2.2 % and 67.6 %, respectively, albeit with a slight compromise in ductility. The cumulative energy dissipation of RX-1 and TX-1 has risen by 22.62 % and 131.99 %, respectively, compared to the unreinforced joint. Notably, the dissipated energy before cracking accounts for 16.50 %, 18.16 %, and 22.29 % of the cumulative energy dissipation<!--> <!-->for the three joints, respectively, highlighting the substantial contribution of crack propagation to energy dissipation under large deformations. The VUSDFLD subroutine based on Cyclic Void Growth Model (CVGM) is embedded into ABAQUS, this subroutine considers the initiation and propagation of joint cracks. Three finite element models with the same dimensions of the specimens were built to simulate the damage process of the joint. The results show that this method can accurately simulate such joints’ cracking and crack growth behavior under cyclic axial load. The simulated hysteresis curve is in good agreement with the test curve.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142421072","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":"Modelling of high frequency vibration of railway bogies’ subcomponent based on structural dynamics: A case study for lifeguard of metro bogie","authors":"","doi":"10.1016/j.engfailanal.2024.108925","DOIUrl":"10.1016/j.engfailanal.2024.108925","url":null,"abstract":"<div><div>The sub-components of railway bogie have been frequently reported to be subjected to the vibration fatigue due to the wheel/rail high frequency vibration. An efficiency numerical model is thus desirable to simulate the high frequency vibration of railway bogie, which can substantially enhance the design efficiency of railway bogie system considering the vibration fatigue. Therefore, this paper aims to proposing a modelling methodology for simulating the high frequency vibration of railway bogies’ subcomponents, and a lifeguard of metro bogie was taken as an example. Firstly, a field test measurement of lifeguard for the metro bogie was primarily introduced to demonstrate the high frequency vibration characteristics and the related failure mechanisms arising from the wheel/rail high frequency impact. Subsequently, a random vibration model for the railway bogie system and the lifeguard based on the rigid/flexible coupled dynamics were developed to simulate the high frequency vibration and the dynamic stress developed at the lifeguard. This method was subsequently employed in the structural optimization for the lifeguard. The results showed that the proposed methodology can effectively simulate the high frequency vibration of lifeguard of bogie system based on the measured axle box acceleration, and the optimized structure can effectively increase the service lifetime under the excitation of wheel/rail high frequency vibration.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142358305","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 of T15 medical orthopedic S46500 stainless steel screwdriver","authors":"","doi":"10.1016/j.engfailanal.2024.108923","DOIUrl":"10.1016/j.engfailanal.2024.108923","url":null,"abstract":"<div><div>A batch of medical orthopedic screwdriver T15 products require a torque of 7.5 N·m, and the torque test after mass production is lower than 6.5 N·m, which cannot meet the process requirements. The fracture morphology and microstructure were characterized by stereo microscope (SM), optical microscope (OM) and field emission electron microscope (SEM), respectively. Their mechanical properties were evaluated by Vickers hardness tester and torque tester. The research results indicate that the failure of T15 screwdriver was predominantly by the mechanism of ductile fracture which occurred at the point of maximum torque force at the outermost shear plane. By increasing the solid solution temperature to 1050 °C and using surface shot peening treatment, microstructure and segregation milling tool marks were eliminated, surface compressive stress was increased, and the torque reached 7.8 N·m.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142358303","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":"The effect of 3D printing orientation on tensile behaviour and fracture mechanisms of Inconel 718","authors":"","doi":"10.1016/j.engfailanal.2024.108920","DOIUrl":"10.1016/j.engfailanal.2024.108920","url":null,"abstract":"<div><div>The manuscript aims to study the effect of 3D printing orientation on the tensile behaviour and fracture mechanisms of samples made of Inconel 718. Components of metals using additive manufacturing techniques are crucial in applications where safety, reliability, and trouble-free operation are essential. Therefore, it is vital to study and understand the behaviour of 3D-printed components under various loading types and predict potential failures. The EOS Nickel Alloy IN718 material sheet provides tensile properties of heat-treated samples (per AMS 5664 procedure) built exclusively in the Z direction. Consequently, the authors extended the investigation to include the tensile behaviour of 3D-printed samples in seven basic orientations within the 3D printing machine’s workspace. For this purpose, the mechanical properties of Inconel 718 alloy samples manufactured using Direct Metal Laser Sintering (DMLS) technology were subjected to uniaxial tensile stress. The samples underwent heat treatment according to the AMS 5664 procedure, with solution annealing and aging temperatures determined using a pseudo-binary phase diagram calculated with Thermo-Calc® software. Post-tensile tests and fracture surface observations were conducted to identify the main failure modes. Microstructural and morphological analyses of 3D-printed INCONEL 718 samples were carried out using light optical microscopy (LOM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) textural analysis. Phase diagrams indicate expected phases such as <em>γ</em>-phase (FCC_A1), <em>δ</em>-phase (NbNi3_D0A), <em>γ’’</em>-phase (Ni3Ti_D024), Laves phase (C14_Laves), and <em>γ</em>’-phase (FCC_L12). Solution annealing was performed above 940 °C while aging treatment was done at temperatures below 800 °C to allow precipitation of <em>γ’</em> and <em>γ’’</em> phases. The <em>δ</em> phase also forms during aging. Fractographic examination of the tensile fractures indicated a predominantly quasi-ductile failure mechanism, with fine-sized dimples observed. In the XZ-oriented samples, the measured yield strength was 11 % higher compared to the Z-oriented samples and the yield strength was more than 12 % higher. The difference in mechanical properties between the Z orientation (Rp_0.2 = 1284 MPa and Rm = 1429 MPa) and the XZ orientation (Rp_0.2 = 1436 MPa and R_m = 1613 MPa) can be mainly attributed to the &lt; 101 &gt; texture in the XZ sample and its more equiaxed grain structure compared to the Z sample.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142358307","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 effects of bilateral laser-assisted cutting on surface integrity and fatigue life of FeCoCrNiAl0.6 alloy","authors":"","doi":"10.1016/j.engfailanal.2024.108921","DOIUrl":"10.1016/j.engfailanal.2024.108921","url":null,"abstract":"<div><div>This study investigates the impact of various cutting parameters in both unilateral and bilateral laser-assisted cutting processes on the surface integrity and fatigue life of FeCoCrNiAl0.6 high-entropy alloy. By utilizing ABAQUS/FE-SAFE simulations and conducting laser-assisted cutting and fatigue tensile tests, differences in surface quality and fatigue life cycles of FeCoCrNiAl0.6 alloy samples under different cutting scenarios were evaluated. The results indicate that in high-speed laser-assisted cutting, an increase in laser speed leads to a progressive decline in surface quality for both unilateral and bilateral methods. Nevertheless, at a laser speed of 4000 mm/s, optimal surface quality is achieved in both approaches, with the bilateral method consistently providing superior results across varying speeds. Regarding residual stress, unilateral laser-assisted cutting at 4000 mm/s produces a surface residual compressive stress of 532 MPa, which is twice as high as that observed at 10000 mm/s. The bilateral method shows a symmetric distribution of residual compressive stress, with peak values of 567 MPa and 528 MPa on the front and back surfaces, respectively. In terms of fatigue life, bilateral laser-assisted cutting demonstrates enhanced performance at 4000 mm/s, achieving a fatigue life cycle that is 4.72 times longer than that of the unilateral method. Overall, bilateral laser-assisted cutting improves the fatigue life of the material through symmetric thermal effects and higher residual compressive stress, particularly at lower laser speeds and optimal cutting depths.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142358308","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}