Engineering Failure Analysis最新文献

{"title":"Lessons learned from a crack assessment of a 36-inch steam header operating at high pressure and temperature","authors":"Roelf Mostert ,&nbsp;Ronald Koenis ,&nbsp;Charl Marais","doi":"10.1016/j.engfailanal.2025.109627","DOIUrl":"10.1016/j.engfailanal.2025.109627","url":null,"abstract":"<div><div>A leaking crack in a high-pressure steam header, manufactured from carbon steel, was assessed for acceptability according to the precepts of the API 579-1/ASME FFS-1 2021 Fitness-For-Service standard. A finite element model, with shell elements in the line section, combined with solid elements in the region of interest, was constructed to gain insight into the through-thickness stress distribution. A basic linear elastic methodology, utilizing a lower-bound estimate of fracture toughness, indicated that the crack was acceptable for continued operation, albeit with a small margin of safety. Five other evaluations, four of which were based on ductile tearing criteria, were performed and it was found that the limiting crack size was in fact larger than the assessed crack with a substantial margin. The most accurate assessment performed used ductile tearing instability as the limiting criterion, with the tearing analysis supported by test results obtained from service-exposed samples. A J-integral tearing resistance (J-R) curve was experimentally established at the operational temperature, using a section cut from the header. The outcomes of the six assessments were critically compared with regard to damage tolerance and conclusions were drawn from these comparisons.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109627"},"PeriodicalIF":4.4,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143886617","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":"Reshaping, performance optimization and failure mechanisms of self-piercing riveted joints in 5083 aluminum alloys under axial compressive loads","authors":"Xianlian Zhang ,&nbsp;Yijin Gao ,&nbsp;Qing Zhang ,&nbsp;Yu Xie","doi":"10.1016/j.engfailanal.2025.109631","DOIUrl":"10.1016/j.engfailanal.2025.109631","url":null,"abstract":"<div><div>In consideration of the drawback of self-piercing riveting (SPR) technology, where the protruding bottom of SPR joint is highly susceptible to be squeezed in practical applications, which subsequently alters the internal forming structure and mechanical performances, the effects of axial compressive loads on SPR joints were investigated through a combination of experiments and numerical simulations systematically. The results indicated that the forming feature of the rivets and sheets could be accurately predicted by the FE model. The compression process may potentially promote the initiation of cracks within the rivet, and the remaining bottom would become a potential weak point in practical applications. The typical cross-sectional parameters were improved apparently with the compressive loads of 60 and 80 kN. The protruding joint bottom was strongly affected and the original coarse grains fined to fibrous structures, which resulted in further plastic deformation and work hardening on the rivet tail and bottom sheet. The compression process can effectively enhance the joint strength, but has a negative impact on the stability of the joint performance and complicates the failure modes. The rivet tail pulled out was the main failure mode for all the joints. The rivet head pulled out and rivet fracture could also occur due to the aggravation of forming defects under higher compressive loads.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109631"},"PeriodicalIF":4.4,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143882697","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 17-4PH crankshaft in three-plunger high-pressure seawater pump","authors":"Weican Wang,&nbsp;Qiyun Mo,&nbsp;Cong Xue,&nbsp;Jiefu Liu,&nbsp;Jize Jiang,&nbsp;Yinshui Liu,&nbsp;Defa Wu","doi":"10.1016/j.engfailanal.2025.109632","DOIUrl":"10.1016/j.engfailanal.2025.109632","url":null,"abstract":"<div><div>This study investigates the fatigue failure of a 17-4PH stainless steel crankshaft in a three-plunger high-pressure seawater pump after 241 h of operation, combining experimental and numerical analyses. First, chemical composition analysis, mechanical property testing, and fracture surface microstructure characterization are conducted on the broken crankshaft to explore the relationship between material properties and heat treatment processes. Next, a three-dimensional transient finite element model is developed to analyze the stress concentration characteristics of the crankshaft under dynamic loading conditions. The results reveal that the failure mode of the fractured crankshaft is high-cycle fatigue, with crack initiation occurring at the crankpin and the crank transition fillet (radius of only 1 mm), where the stress amplitude reaches 184 MPa—significantly higher than in other areas. Material testing shows that while the yield strength (1038 MPa) and tensile strength (1221 MPa) of 17-4PH stainless steel meet technical standards, the post-fracture elongation (5.0 %) and reduction of area (8 %) are far below the design values (≥13 % and ≥45 %, respectively). This suggests that inadequate heat treatment results in insufficient material toughness, accelerating fatigue crack propagation. Further numerical simulations demonstrate that optimizing the heat treatment process can significantly increase the residual austenite content and toughness, improving the safety factor of the critical section from 0.59 to 1.649 and extending the fatigue life into the theoretically infinite life range. This study presents a fatigue life prediction method integrating transient stress field analysis with material performance optimization. It provides a theoretical basis and practical guidance for the design optimization, heat treatment process control, and reliability assessment of crankshafts in deep-sea high-pressure environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109632"},"PeriodicalIF":4.4,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143891360","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":"Cavitation-induced damage in high-speed railway CRTSⅢ ballastless track: Mechanism and numerical insights","authors":"Guihong Xu ,&nbsp;Wenbo Deng ,&nbsp;Shixin Ran ,&nbsp;Li He ,&nbsp;Li Duan ,&nbsp;Caiyou Zhao ,&nbsp;Juan Juan Ren ,&nbsp;Mingwei He","doi":"10.1016/j.engfailanal.2025.109628","DOIUrl":"10.1016/j.engfailanal.2025.109628","url":null,"abstract":"<div><div>The high-speed railway CRTSⅢ ballastless track, subjected to complex strip structural systems, high-cycle fatigue loads, and intricate rainwater environments, faces significant maintenance challenges due to interlayer disconnection and crack propagation. This study investigates the cavitation and dehollowing damage mechanisms in rainy areas, focusing on the water dynamics within track interlayer cracks. Numerical simulations using ANSYS-FLUENT software were conducted to analyze the cavitation phenomenon and its impact on the structural integrity of the track. The findings provide insights into the damage progression in rainy regions and contribute to a better understanding of the underlying mechanisms.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"177 ","pages":"Article 109628"},"PeriodicalIF":4.4,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144070086","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":"Comparative study of hydrogen embrittlement in 310S, 304L, and 316L stainless steels under in situ electrochemical hydrogen charging. Part 1: Experimental study","authors":"Byeong-Kwan Hwang ,&nbsp;Hee-Tae Kim ,&nbsp;Seung-Joo Cha ,&nbsp;Gi-Seung Park ,&nbsp;Ji-Tae Yoon ,&nbsp;Jeong-Hyeon Kim ,&nbsp;Jae-Myung Lee","doi":"10.1016/j.engfailanal.2025.109641","DOIUrl":"10.1016/j.engfailanal.2025.109641","url":null,"abstract":"<div><div>The microstructure and hydrogen embrittlement behavior of the austenitic stainless steels STS310S, STS304L, and STS316L were investigated under hydrogen charging conditions. The steels were charged at various current densities ranging from 0.25 to 15 mA/cm². The analysis was conducted using a slow strain-rate tensile (SSRT) test on notched specimens under in situ electrochemical hydrogen charging. The results indicated that hydrogen embrittlement effects emerged after the elastic region, with mechanical properties deteriorating as the current density increased. The critical current densities for mechanical property degradation were determined to be 5, 2, and 10 mA/cm² for STS310S, STS304L, and STS316L, respectively. Hydrogen concentration increased with current density, following a power-law relationship, with critical hydrogen concentrations of 35.80, 24.00, and 28.80 wppm, respectively. STS310S, with the highest Ni equivalent, retained ductile fracture behavior and demonstrated superior resistance to hydrogen embrittlement. In contrast, STS304L, with the lowest Ni equivalent, exhibited the highest susceptibility, transitioning to brittle fracture with extensive secondary cracking, while STS316L showed intermediate behavior, balancing ductility and brittleness. Fractographic and EBSD analyses confirmed that a higher Ni equivalent stabilizes the FCC phase and mitigates phase transformation to martensite, enhancing resistance to hydrogen embrittlement. These results indicate that alloy composition, particularly the Ni equivalent, plays a crucial role in the development of hydrogen resistant materials.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109641"},"PeriodicalIF":4.4,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143879183","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 fatigue life prediction method for the laser deposition repaired TA15 component with annealing heat treatment","authors":"Song Zhou ,&nbsp;Zhaoxing Qian ,&nbsp;Zhenjun Zhang ,&nbsp;Xin Bai","doi":"10.1016/j.engfailanal.2025.109649","DOIUrl":"10.1016/j.engfailanal.2025.109649","url":null,"abstract":"<div><div>The fatigue properties are very important for the laser deposition repaired TA15 component with annealing heat treatment (named as LDR &amp; AHT TA15) used in aerospace. However, the current fatigue life prediction methods can not predict the fatigue life of the LDR &amp; AHT TA15 component due to the limitation of the fatigue damage model or the experimental data accuracy. To predict the fatigue life of the LDR &amp; AHT TA15 component, a new fatigue prediction model with considering annealing heat treatment (named as FLRA model) is established based on the fatigue physics of the microstructure transformation. Then a new fatigue life prediction method (named as EFL method) based on the FLRA model is proposed. By comparing with the experimental fatigue life of the LDR &amp; AHT TA15 and the traditional method, the FLRA model and the EFL method show high accuracy and strong robustness (i.e. the location of stress concentration, the location of the maximum cumulative damage and the accumulation of the damage value). Furthermore, the parameters of the FLRA model are illustrated in microstructure fatigue physics.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"177 ","pages":"Article 109649"},"PeriodicalIF":4.4,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143923405","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 behavior of as-cast and heat-treated Mg-Gd-Y-Er alloy at room temperature","authors":"Sudharsan S ,&nbsp;Raja Annamalai A","doi":"10.1016/j.engfailanal.2025.109652","DOIUrl":"10.1016/j.engfailanal.2025.109652","url":null,"abstract":"<div><div>In this study, the fatigue behavior of the Mg-Gd-Y-Er alloy has been investigated under cast, T4, and T6-treated conditions. The high-cycle fatigue (HCF) test was conducted at room temperature, with a frequency of 15 Hz and a stress ratio of 0.1. The as-cast and T4-treated samples exhibit a fatigue strength of 51 MPa at 10⁵ cycles. At the same time, the T6-treated samples show fatigue strengths of 55 MPa and 68 MPa, which are 7 % and 33 % higher than the fatigue strength of the as-cast alloy. The fractured surface reveals the brittle mode of fracture in both conditions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109652"},"PeriodicalIF":4.4,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143886616","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":"Microstructure deformation and failure mechanism of laser direct energy deposited Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy: experimental and numerical simulation","authors":"Kong Xiangyi ,&nbsp;Zhou Xinbo ,&nbsp;Cao Jun ,&nbsp;Zhang Jikui","doi":"10.1016/j.engfailanal.2025.109650","DOIUrl":"10.1016/j.engfailanal.2025.109650","url":null,"abstract":"<div><div>Additive manufacturing has emerged as a highly attractive technique in fabricating large-scale and complex integral titanium alloy structures. Understanding the failure behavior of additively manufactured alloy is crucial for ensuring the structural integrity and safety of primary load-carrying components. In this study, an in-situ tensile test combined with an image-based micromechanics finite element model was employed to investigate the microstructure deformation behavior and failure mechanisms of laser direct energy deposited (LDED) titanium alloy. The LDED Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy exhibits a unique bimodal microstructure, comprising coarse lamellar primary α phase and transformed β phase matrix. During the elastic stage, the primary α phase exhibits high stresses and low strains, while the transformed β phase exhibits the opposite behavior. As the applied load increases, strain localization first occurs in the fine transformed β phase between two parallel primary α phases, leading to an earlier yield of the transformed β phase even though the alloy as a whole remains in the linear elastic regime. The yield of the majority of the transformed β phase is identified as the primary cause for the yield of tested specimen.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109650"},"PeriodicalIF":4.4,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143879182","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":"Deformation behavior, microstructure evolution, and creep damage mechanism of the novel 9Cr-3W-3Co-1CuVNbB steel CMT+P welded joint during creep","authors":"Lipeng Cai ,&nbsp;Lei Zhao ,&nbsp;Lianyong Xu ,&nbsp;Yongdian Han ,&nbsp;Kangda Hao ,&nbsp;Haoyu Cai","doi":"10.1016/j.engfailanal.2025.109642","DOIUrl":"10.1016/j.engfailanal.2025.109642","url":null,"abstract":"<div><div>To promote the widespread application of 9Cr-3W-3Co-1CuVNbB steel in ultra-supercritical (USC) power plants, this study systematically investigated the creep deformation behavior, microstructural evolution, and damage mechanisms of its welded joints. The results showed that welded joints prepared using Cold Metal Transfer with Pulse (CMT+P) exhibited superior creep resistance compared to those fabricated using Electron Beam Welding (EBW). Analysis based on Norton’s power law indicated that the deformation mechanisms of the welded joints were highly stress-dependent: under high-stress conditions, creep deformation was primarily governed by back stress, whereas under low-stress conditions, it was dominated by dislocation motion. Specifically, under high-stress creep conditions, the welded joints exhibited excellent microstructural stability, with fractures occurring in the weld metal (WM). Transmission electron microscopy (TEM) analysis revealed that dislocations accumulated extensively at martensitic laths (MLs) interfaces, leading to cracking of the lath structure. In contrast, under low-stress creep conditions, the intercritical heat-affected zone (ICHAZ) became the weak point. Dislocation tangles formed around coarsened precipitates, promoting cavity nucleation. As creep progressed, these cavities expanded along the precipitate/matrix interfaces and interconnected, eventually forming macroscopic cracks and cavity bands, ultimately resulting in brittle Type IV cracking. Classical nucleation theory analysis further indicated that dislocation density gradients and M₂₃C₆ carbide coarsening were the primary factors accelerating precipitate coarsening. This study innovatively established a composite creep damage mechanism incorporating both back stress and dislocation motion deformation mechanism, elucidating the competitive damage mechanisms of CMT+P welded joints under multi-stress fields.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109642"},"PeriodicalIF":4.4,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143879184","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 preliminary conceptual study for coupled thermo-mechanical and structural characterization of rim-supported run-flat tires","authors":"Behzad Hamedi ,&nbsp;Abhishek Saraswat ,&nbsp;Jeff Warfford ,&nbsp;Cameron Garman ,&nbsp;William V. Mars ,&nbsp;Saied Taheri","doi":"10.1016/j.engfailanal.2025.109617","DOIUrl":"10.1016/j.engfailanal.2025.109617","url":null,"abstract":"<div><div>Rim-supported inserts in run-flat tires (RSS RFTs) ensure extended mobility after a blowout, offering at least 50 miles of operation at 45 mph under zero-pressure conditions. However, excessive heat generation during deflation accelerates rubber aging and degrades performance. To address this, a validated 3D finite element model, coupled with Abaqus/CAE and Endurica co-simulations, is used to analyze strain distribution, contact patch characteristics, and thermo-mechanical behavior.</div><div>Results reveal high strain and heat generation concentrated in the contact patch center, intensifying material degradation and the risk of premature failure. Strain redistribution mechanisms, shifting strain from the footprint and inner liner zones toward the sidewall, enhance durability and mobility under repeated loading or deflation scenarios. The methodology optimizes insert designs to mitigate localized stresses, deformation, sidewall warpage, and thermal issues, thereby extending fatigue life in deflated conditions.This study highlights critical design factors influencing the durability and performance of rim-supported run-flat tires (RSS RFTs). Simulation-driven methodologies are employed to evaluate and optimize key parameters such as durability, contact patch footprint area, pressure distribution, radial stiffness, and overall operational efficiency. A nonlinear FEA model in Abaqus/CAE accurately simulates large deformations, material behavior, and tire geometry, validated through mesh convergence studies, sensitivity analyses, and failure mechanism evaluations under diverse loading conditions. Predicted fatigue life and thermal performance align with prior studies, confirming the reliability of the approach and its potential for real-world application.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109617"},"PeriodicalIF":4.4,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143882589","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}