Engineering Failure Analysis最新文献

{"title":"Study on the impact toughness and crack propagation behavior of Ti microalloyed weathering steel laser-MAG hybrid welded joints","authors":"Haizhou Li ,&nbsp;Dirui Wang ,&nbsp;Wantong Wang ,&nbsp;Rui Lu ,&nbsp;Qiang Fang ,&nbsp;Chuangwei Wang ,&nbsp;Zhengrong Li ,&nbsp;Han Zeng ,&nbsp;Hui Chen","doi":"10.1016/j.engfailanal.2024.109030","DOIUrl":"10.1016/j.engfailanal.2024.109030","url":null,"abstract":"<div><div>In this work, the effect of Ti microalloying on the impact toughness of weathering steel laser-MAG hybrid welded joints was investigated and the corresponding crack initiation and propagation mechanisms were revealed. The results show that the impact toughness of heat affect zone (HAZ) increased by 39.4% and weld metal (WM) by 70.9% compared to Ti-free weathering steel welded joints. The degree of improvement in impact toughness gradually increases with the direction from BM (base metal) to WM. In the WM, Ti element can refine the precipitations and reduce the shape and size of M−A constituents. Furthermore, the microstructure in the WM exhibits the obvious preferred orientations, i.e., the maximum IPF intensity value are concentrated around the [111] pole (the slip direction of BCC structure), which is more prone to slip under external forces. In the HAZ, the addition of Ti mainly plays a role in decreasing the size of precipitations, inducing AF precipitation and increasing the homogeneity of grain size. Therefore, the impact toughness of WM and HAZ for Ti microalloyed weathering steel welded joints is improved by hindering the crack propagation. In addition, in the WM, the main crack path is flatter and the number of secondary cracks is more than that in the HAZ, indicating that the impact toughness of WM is poorer.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109030"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142587436","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":"Surface integrity and fatigue failure behavior of nickel based alloy blades: After cutting, vibration finishing and shot peening","authors":"Yunqi Sun ,&nbsp;Changfeng Yao ,&nbsp;Liang Tan ,&nbsp;Minchao Cui ,&nbsp;Tao Fan ,&nbsp;Yilong Cao ,&nbsp;Yaoguo Ma","doi":"10.1016/j.engfailanal.2024.109034","DOIUrl":"10.1016/j.engfailanal.2024.109034","url":null,"abstract":"<div><div>This article selected three processes to prepare nickel based alloy GH4169G blades, tested the surface integrity changes of different processes, conducted high cycle vibration fatigue tests, and studied their failure mechanisms. The results indicate that the milling polishing vibration precision machining (MV) process can effectively reduce the surface roughness of milling (M) process blades, while the milling polishing vibration precision machining shot peening (MVSP) process significantly improves the residual compressive stress and hardening layer level of blades. The MVSP process blades have the best vibration fatigue life, with an average life of 4.91 × 10⁶, which is 775.2 % higher than the M process blades. The fatigue life of the blades has been significantly improved. After MV process treatment, the blade undergoes a transition from multi-source fatigue caused by M process to surface single source fatigue crack initiation. The crack initiation location of MVSP process blades shifted from the surface to about 0.097 mm below the surface, and shot peening significantly improved the fatigue crack initiation life of the blades.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109034"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660946","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 performance and failure mechanism of ductile iron pipes with socket joints under traffic loads","authors":"Wei Liu ,&nbsp;Wanli Cui","doi":"10.1016/j.engfailanal.2024.109004","DOIUrl":"10.1016/j.engfailanal.2024.109004","url":null,"abstract":"<div><div>Urban water supply pipelines experience repetitive traffic loads during their operational lifespan, potentially leading to fatigue failure. However, existing research focuses primarily on the static or dynamic mechanical responses of pipes, with limited studies on the fatigue performance of pipes. This study investigates the fatigue performance and failure mechanism of DN200 ductile iron (DI) pipes with socket joints under traffic loads and water pressure through bending fatigue tests. First, the mechanical responses of pipe joints under traffic loads derived from statistical data on highway traffic loads, soil pressure, and self-weight are calculated using ABAQUS to give the fatigue test load amplitude. Subsequently, tests are conducted on three DN200 DI pipes under a water pressure of 0.2 MPa: one for a monotonic test and two for fatigue tests under extra car and bus loads, respectively. The fatigue life of pipes under various traffic load combinations is analyzed using cumulative damage theory. Moreover, the relationship between fatigue load amplitude and number of cycles for DN200 DI pipes are obtained on the basis of the test data. Results show that the maximum rotation angle of joint is an important indicator of failure. Finally, a theoretical method for calculating the joint angle is proposed on the basis of geometric dimensions. A good agreement between the test and theoretical results is observed. Thus, the proposed method can obtain the fatigue performance of joints effectively.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109004"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660942","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 mechanism and crack propagation behavior of turnout stock rail in high-speed railway","authors":"Qiang Yi ,&nbsp;Xiaolong Liu ,&nbsp;Shuguo Wang ,&nbsp;Haiyang Chang ,&nbsp;Zhuopeng Jiang ,&nbsp;Wengjing Wang","doi":"10.1016/j.engfailanal.2024.109026","DOIUrl":"10.1016/j.engfailanal.2024.109026","url":null,"abstract":"<div><div>Turnouts are crucial equipment for ensuring the safety of high-speed railways. The wheel-rail impact force is more obvious and the structural stress distribution is more complex in turnout area comparing with main lines. Fatigue failures of stock rail in high-speed railway turnout occurred after long-term service. A failure analysis by experimental and simulation methods was conducted to reveal the failure mechanism of the stock rail in the switch panel of railway turnout. First, the fracture surface of the failed stock rail was observed, indicating that the crack initiated from the rail bottom. Combing with the finite element modeling of the switch structure of the turnout, it was found that the stress of rail bottom at the fastening position of the slide chair is high, causing the crack initiation. Additionally, the effects of crack size and load on crack propagation of the stock rail was investigated by bench tests and simulation. It was noted that the crack propagation rate increased significantly with greater crack size and higher load. Moreover, the damage tolerance of the crack at the stock rail bottom was defined as 7 mm which is before the rapid propagation of cracks.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109026"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660885","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 deteriorated tribological and noise performances of copper-based brake pads induced by the increased content of flake graphite","authors":"Peng Zhang ,&nbsp;Dongbin Wei ,&nbsp;Xiangying Ding ,&nbsp;Lin Zhang ,&nbsp;Xuanhui Qu","doi":"10.1016/j.engfailanal.2024.109033","DOIUrl":"10.1016/j.engfailanal.2024.109033","url":null,"abstract":"<div><div>Enhancing the lubricity of copper-based brake pads has been viewed as a crucial strategy to boost braking performance. Flake graphite and the oxide film are two substances that are widely concerned with providing lubrication at the friction interface. However, the results from full-scale dynamometer in this work indicate that the increased content of flake graphite with stronger lubrication and iron particles that accelerate the generation of oxide film lead to a deterioration in tribological and noise performance. This is manifested by high sensitivity to clamping force, significant fading behavior, increased sound pressure level and high-frequency noise. The evidence from the worn surface suggests that flake graphite is susceptible to peeling off from the friction surface, thereby amplifying the instability of the friction surface. The unstable existence of both flake graphite and oxide film during emergency braking actually diminishes the lubrication of the friction interface, likely resulting in the degraded braking performance. The indication suggests that the development of high-performance copper-based brake pads should aim to achieve a harmonization of diverse properties, rather than emphasizing only specific aspects.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109033"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142579054","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":"Solder joint lifetime model using AI framework operating on FEA data","authors":"Mohd Zubair Akhtar,&nbsp;Maximilian Schmid,&nbsp;Andreas Zippelius,&nbsp;Gordon Elger","doi":"10.1016/j.engfailanal.2024.109032","DOIUrl":"10.1016/j.engfailanal.2024.109032","url":null,"abstract":"<div><div>The thermo-mechanical reliability of electronic systems is often limited by the crack growth within the solder joints. Addressing this issue requires careful consideration of the design of the package and solder pads. Finite Element Analysis (FEA) is widely used to predict crack growth and to model their lifetime. Traditionally, FEA post-processing methods rely on human expertise to select appropriate regions for evaluating plastic and creep strain at critical locations and correlating these values with experimental data using the Coffin-Manson equation, which predicts fatigue lifetime based on cyclic plastic strain. This study introduces a novel method for FEA post-processing of surface-mounted devices (SMD) on printed circuit boards (PCB) using artificial intelligence. The method transforms the FEA data into a 2D grid map of creep strain values and employs a Convolutional Neural Network (CNN) for automatic feature extraction. Afterwards, a fully connected layer correlates the extracted features with the experimental measured solder joint lifetime, effectively capturing nonlinear relationships.</div><div>The study focuses on the development of the concept of crack formation in the solder interconnects of ceramic based high-power LED packages used in the automotive industry for headlights. The validated FEA model is based on an extensive data set of 1800 LED packages including seven different ceramic-based LED packages and five different solders. The design of the ceramic LED package covers two-pad and three-pad footprint for soldering and thin film and thick film metallized ceramic carriers. Results show a strong agreement (R² Score is 99.867 %) between simulations and experimental data for ceramic LED packages. This automatic feature extraction from FEA data sets a new benchmark for improving solder reliability predictions, and it has proved to be better than established methods for lifetime prediction of solder joints.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109032"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142573109","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":"Calculation method and experimental research on strand breakage in large cross-section conductors considering contact between strands","authors":"Qin Jian ,&nbsp;Qiao Liang ,&nbsp;Qi Zhiqiang ,&nbsp;Liu Chen ,&nbsp;Zhang Feikai","doi":"10.1016/j.engfailanal.2024.109020","DOIUrl":"10.1016/j.engfailanal.2024.109020","url":null,"abstract":"<div><div>This paper proposes a numerical method for the strand breakage defect in large cross-section conductors during tension stringing construction. First, the contact types between strands in the same layer and adjacent layers of the conductor were analyzed. The relationship between the force and depth of strand contact was then determined. The structural calculation method for straight conductor under tensile and torsional loads was proposed considering in the contact between strands, which can obtain the accurate calculation results of strands in different layers. The method avoids the establishment of complex multi-strand models and the setup of large number contact pairs, and has a much higher computational efficiency than finite element method (FEM), the performance gap is up to 300 times. For 630 mm² conductor, the calculated results of strands demonstrated significant changes in the axial forces of strands of different layers under positive and negative torque, which substantially influences the strand breakage patterns. Through the analysis of the mechanical cause of strand breakage, a calculation formula for the axial force of strands were proposed based on the deformation process as the conductor passes through the stringing block. The results of 630 mm² conductor indicated that the torque and tension on the conductor are critical factors of the strand breakage. Referencing the actual engineering conditions, a test setup was designed to simulate the conductor passing through the block, and the breakage defect of strand was reproduced. The forms and locations of the breakage defects observed in the tests were consistent with the calculated results, validating the alignment of the theoretical analysis with actual states. This proposed method can be applied to analyze the strand defect of conductor with various cross-sections, which offers a theoretical foundation for the prevention and control of construction defect in the transmission line.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109020"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660943","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 surface morphology changes in stainless steel through stepwise cavitation erosion: A comprehensive study","authors":"Osman Omran Osman ,&nbsp;S.M. Ahmed","doi":"10.1016/j.engfailanal.2024.109017","DOIUrl":"10.1016/j.engfailanal.2024.109017","url":null,"abstract":"<div><div>Cavitation damage, evolution, and features with time are serious problems confronting designers and users of high-speed hydraulic machines. The stepwise erosion technique clarifies the evolution of cavitation damage and its features over time. The technique involves exposing a test sample to repeated very low durations of erosion, followed by accurate relocation in the SEM. This allows fora detailed study of the actual wear processes within a material, providing a solid foundation for understanding material failure. The experiments were conducted using an ultrasonic vibratory horn functioning at 19.5 kHz frequency and 50 µm ± 0.2 um peak-to-peak amplitude. The tested material was cold-rolled austenitic stainless steel SUS 304 (18 Cr-8 Ni). The results show that the slip bands formed due to shock waves’ impact are the preferential sites for early material removals. Material removal starts gradually along the slip bands that form at the grain boundary and then progresses into the grain. The results also showed that the microjets formed pits that were a few micrometers in size and separated from one another. These pits have remained the same shape and size over time, confirming their limited role in the evolution of cavitation damage. The initiation and progression of inherent cracks resulting from plastic deformation, as well as the characteristics of dislodged particles, strongly support the conclusion that shockwave impacts cause fatigue failure as the mechanism of cavitation erosion.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109017"},"PeriodicalIF":4.4,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142573110","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":"Effects of irregular holes on load-bearing mechanism and capacity in prestressed concrete cylinder pipes","authors":"Guofu Zhao ,&nbsp;Jun Lu ,&nbsp;Kai Su ,&nbsp;Junmiao Xiao ,&nbsp;Jie Li ,&nbsp;Pan Ming ,&nbsp;Yueyang Sun ,&nbsp;Miaoyan Liu ,&nbsp;Siyao Wang","doi":"10.1016/j.engfailanal.2024.109006","DOIUrl":"10.1016/j.engfailanal.2024.109006","url":null,"abstract":"<div><div>This study investigates the effects of irregular holes on the load-bearing mechanism and capacity of prestressed concrete cylinder pipes (PCCP). An internal pressure test was performed on a PCCP specimen containing multiple irregular holes, and a finite element numerical simulation was conducted to explore the impact of these holes. The results indicated that the presence of irregular holes caused significant anisotropic stress distribution, particularly at the inner wall of the concrete core, with stress concentrations around the holes. Cracks were initiated near the spigot end and propagated axially as the internal pressure increased. The load-bearing process of the PCCP evolved in three stages: (1) the prestressed wires bore the majority of the load, (2) the concrete began sustaining a portion of the load as it experienced tensile stress, and (3) the concrete underwent plastic damage, transferring the load to the steel cylinder and prestressed wires. The internal pressure of PCCP model with multiple irregular holes associated with the serviceability limit-states was 0.23 MPa, representing only 26.4 % of the intact model, which was 0.87 MPa. However, the difference in ultimate load-bearing capacity between the two models was minimal. These findings underscore the necessity of timely repairs to prevent the worsening of erosion in PCCPs with irregular holes.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109006"},"PeriodicalIF":4.4,"publicationDate":"2024-10-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593150","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":"Role of residual stress in the failure of the bend of superheater Cr-Mo steel tube working in high-temperature conditions","authors":"Mária Hagarová ,&nbsp;Pavel Peterka ,&nbsp;Gabriela Baranová ,&nbsp;Martin Fujda ,&nbsp;Dávid Csík ,&nbsp;Iveta Vasková ,&nbsp;Pavol Lengvarský ,&nbsp;Ivan Petryshynets","doi":"10.1016/j.engfailanal.2024.109018","DOIUrl":"10.1016/j.engfailanal.2024.109018","url":null,"abstract":"<div><div>This study deals with the material analysis of a Cr-Mo steel superheater at the bending point. The crack occurred on the inside of the bend after 4,300 h of boiler operation, which resulted in a leak of the working medium and a forced device shutdown. The planned service life of the superheater tubes was 34,000 h. The operating parameters of the boiler were as follows: steam output pressure 3.2–3.6 MPa, steam output temperature 440–450 °C. Cracks were found on the lateral surfaces of the bends of the superheater lower tubes. Visual, microscopic, and EDS SEM analyses were performed to determine the cause of the damage. Microscopic analysis showed that crack initiation occurred near the maximum bend on the inner surface of the tubes, where the present pits acted as stress concentrators. EDS SEM confirmed that the predominant iron content in the corrosion layer was related to the formation of tubercles above the corrosion pits, which participated in the corrosion-mechanical nature of the failure. The calculated residual stress values were significant and concentrated in both the intrados and extrados bending regions of the tube. Finite element model (FEM) was used to locate the post-bending stress distribution of the tube and confirmed that a combination of post-bending residual stresses, steam pressure and temperature, and steel tube pitting caused cracks to form and propagate. The distribution of local mechanical stresses through a cross-section of the wall thickness of the superheated tube was experimentally carried out using an electron backscattered diffraction (EBSD) analysis. The<!--> <!-->obtained results were correlated with the Mises residual stress.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"167 ","pages":"Article 109018"},"PeriodicalIF":4.4,"publicationDate":"2024-10-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593148","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}