Engineering Failure Analysis最新文献

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Investigation of high‑temperature tensile damage behavior and fracture mechanisms in DC53 tool steel DC53工具钢高温拉伸损伤行为及断裂机制研究
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-04 DOI: 10.1016/j.engfailanal.2025.110188
Gang Hu , Chaoyu Yang , Haiming Zhao
{"title":"Investigation of high‑temperature tensile damage behavior and fracture mechanisms in DC53 tool steel","authors":"Gang Hu ,&nbsp;Chaoyu Yang ,&nbsp;Haiming Zhao","doi":"10.1016/j.engfailanal.2025.110188","DOIUrl":"10.1016/j.engfailanal.2025.110188","url":null,"abstract":"<div><div>To elucidate the high-temperature damage and fracture mechanisms of DC53 tool steel during cutter ring hot forming, high-temperature tensile tests were performed on notched specimens. Instead of a single condition, a range of temperatures (1000–1060 °C), strain rates (0.05–5 s<sup>−1</sup>), and notch radii (2.5–30 mm) was investigated. The fracture morphologies and microstructures of the specimens were examined using optical microscopy and scanning electron microscopy. The results show that the peak tensile load of DC53 steel increases with decreasing temperature and increasing strain rate. Its ductility and fracture strain are enhanced with increasing temperature and strain rate. Under low stress triaxiality, DC53 steel exhibits pronounced brittleness. With increasing temperature and strain rate, the fracture mechanism gradually shifts from brittle to ductile. At low stress triaxiality, dynamic recrystallization is suppressed, resulting in coarse intergranular fracture features and a significant reduction in ductility. Voids preferentially nucleate at carbides, while their growth and coalescence are significantly inhibited under conditions of intensive dynamic recrystallization. Based on these findings, a high-temperature damage and fracture model for DC53 tool steel is proposed.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110188"},"PeriodicalIF":5.7,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266472","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}
引用次数: 0
Tribological failure mechanisms and mitigation strategies for bevel gear differentials in electric vehicles 电动汽车锥齿轮差速器的摩擦学失效机理及缓解策略
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-04 DOI: 10.1016/j.engfailanal.2025.110158
Hui Zhou , Xiaotian Li , Ruixue Sun , Xianping Li , Benzhu Zhang , Mengqi Zhang , Jiliang Mo
{"title":"Tribological failure mechanisms and mitigation strategies for bevel gear differentials in electric vehicles","authors":"Hui Zhou ,&nbsp;Xiaotian Li ,&nbsp;Ruixue Sun ,&nbsp;Xianping Li ,&nbsp;Benzhu Zhang ,&nbsp;Mengqi Zhang ,&nbsp;Jiliang Mo","doi":"10.1016/j.engfailanal.2025.110158","DOIUrl":"10.1016/j.engfailanal.2025.110158","url":null,"abstract":"<div><div>During start-up, rapid acceleration, and energy regeneration (involving alternating forward and reverse rotation), electric vehicle (EV) drivetrains-including reduction gears and differentials-are subjected to higher instantaneous torque loads, significantly increasing the risk of component failures such as wear compared to internal combustion engine vehicles. Investigating wear failures and their mechanisms in differentials under high-load conditions is essential for enhancing the operational safety and stability of EVs. In this study, a durability bench test was conducted on the differential of a specific EV model under differential-speed and torque-bias conditions. The wear behavior of key components was analyzed and characterized. Experimental results revealed typical wear failures such as circumferential furrow, adhesive wear, and plastic deformation on the planetary gear shafts and the inner bores of the planetary gears. Contact behavior analysis indicated that the overturning displacement of the planetary bevel gears under meshing force causes localized contact pressure concentrations at the shaft-bore interfaces, which are likely the main cause of the observed surface wear. Modifying the geometry of the planetary gear bore (i.e., surface modification) was found to be an effective strategy for relieving stress concentrations. An optimal modification amount exists that minimizes contact pressure at the shaft-bore interface without introducing new stress concentration zones. The findings not only elucidated the failure mechanism, but also yielded operative geometric optimization strategies based thereon, thereby providing theoretical underpinnings for anti-wear design and service life enhancement of electric vehicle differentials.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110158"},"PeriodicalIF":5.7,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266198","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}
引用次数: 0
Stress-medium synergistic hot corrosion failure mechanism and kinetics model of a Ni-based superalloy ni基高温合金应力-介质协同热腐蚀失效机理及动力学模型
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-04 DOI: 10.1016/j.engfailanal.2025.110187
H.Q. Pei, T. Zuo, J.Y. Wang, H. Zhang, Z.X. Wen, S.F. Wen, Z.F. Yue
{"title":"Stress-medium synergistic hot corrosion failure mechanism and kinetics model of a Ni-based superalloy","authors":"H.Q. Pei,&nbsp;T. Zuo,&nbsp;J.Y. Wang,&nbsp;H. Zhang,&nbsp;Z.X. Wen,&nbsp;S.F. Wen,&nbsp;Z.F. Yue","doi":"10.1016/j.engfailanal.2025.110187","DOIUrl":"10.1016/j.engfailanal.2025.110187","url":null,"abstract":"<div><div>The hot corrosion behavior of a Ni-based superalloy was investigated under tensile stresses of 0, 60, and 120 MPa at 750 °C using XRD, OM, SEM, and EDS. The corrosion medium consisted of a 75 % Na<sub>2</sub>SO<sub>4</sub>–25 % NaCl salt mixture. The influence of tensile stress on oxide film microstructure, elemental diffusion, and corrosion kinetics was systematically analyzed. Results revealed that tensile stress accelerated hot corrosion via two key mechanisms: (1) enhancing the bidirectional diffusion of Cr and S, and (2) degrading the oxide film’s integrity. The thickness of Cr-depleted layers, which varied with applied stress, served as a quantitative indicator of corrosion kinetics. The corrosion process progressed through three distinct stages, corresponding to oxide film growth, cracking/spalling, and reformation. A synergistic degradation mechanism was proposed, combining stress and hot corrosion effects. Outward Cr diffusion initially formed a protective Cr<sub>2</sub>O<sub>3</sub>-rich layer, but tensile stress and corrosive salts jointly shortened its protective lifespan. Subsequent Cr<sub>2</sub>O<sub>3</sub> spalling enabled deeper salt penetration, inducing grain boundary embrittlement and accelerated substrate degradation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110187"},"PeriodicalIF":5.7,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266202","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}
引用次数: 0
Unexpected softening in helical compression springs: Experimental Characterization and numerical modeling of longitudinal wire cracks 螺旋压缩弹簧的意外软化:纵向钢丝裂纹的实验表征和数值模拟
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-03 DOI: 10.1016/j.engfailanal.2025.110159
Hugo Font , Guillaume Cadet , Manuel Paredes
{"title":"Unexpected softening in helical compression springs: Experimental Characterization and numerical modeling of longitudinal wire cracks","authors":"Hugo Font ,&nbsp;Guillaume Cadet ,&nbsp;Manuel Paredes","doi":"10.1016/j.engfailanal.2025.110159","DOIUrl":"10.1016/j.engfailanal.2025.110159","url":null,"abstract":"<div><div>Cylindrical helical compression springs were experimentally found to exhibit significant softening — up to 40% loss in stiffness — despite having passed all conventional quality control procedures, including tensile tests, chemical analysis, wire and spring coiling trials, and visual inspections. Unlike documented failure modes that typically involve wire rupture under static or fatigue loading, these springs remained intact, making the anomaly difficult to identify. A multi-technique investigation combining optical and electron microscopy, dye penetrant testing, eddy current inspection, and X-ray tomography revealed a continuous longitudinal crack along the wire. This axial defect, introduced during wire drawing, had a depth close to the wire radius and a sub-micrometric width, placing it at the edge of detectability. Numerical simulations confirmed that such cracks do not affect the wire’s response in tensile or bending loading — explaining why traditional inspections failed — but significantly reduce torsional stiffness. Analytical models from the literature were compared with simulations; some were validated, and a simplified model was proposed. The role of torsional warping in setting the softening limit was also clarified. Finally, a parametric study on crack positioning along the wire’s circumference showed that while overall stiffness was only slightly affected, internal stress flow was notably disrupted when the crack lay on highly stressed fibers. This study is the first to report and explain the mechanical effects of longitudinal cracking in compression springs. The findings offer practical insights for improving defect detection and mechanical prediction in drawn wire products.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110159"},"PeriodicalIF":5.7,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145265523","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}
引用次数: 0
Simulation-derived semantic features enabling zero-shot domain adaptation for rail fastener failure detection in unseen scenarios 仿真衍生的语义特征,使零射击域适应轨道紧固件故障检测在未知的场景
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-03 DOI: 10.1016/j.engfailanal.2025.110186
Shaohua Wang , Minjung Kim , Gen Li , Lihua Tang , Kean C. Aw
{"title":"Simulation-derived semantic features enabling zero-shot domain adaptation for rail fastener failure detection in unseen scenarios","authors":"Shaohua Wang ,&nbsp;Minjung Kim ,&nbsp;Gen Li ,&nbsp;Lihua Tang ,&nbsp;Kean C. Aw","doi":"10.1016/j.engfailanal.2025.110186","DOIUrl":"10.1016/j.engfailanal.2025.110186","url":null,"abstract":"<div><div>Rail fasteners are crucial components in maintaining the structural integrity of railway infrastructure, and timely identification of fastener failures is essential for ensuring operational safety. Conventional deep learning methods for structural health monitoring rely heavily on extensive labelled failure data for effective model training. This becomes particularly challenging when dealing with early-stage failures (e.g., fastener loosening), where such labelled data may be scarce or unavailable. To address this issue, we propose a simulation-derived semantic features enabling zero-shot domain adaptation (SSFZSDA) method, designed to enhance the generalization capabilities by transferring learned semantic features from simulated datasets to unlabelled real-world datasets. Specifically, semantic features that implicitly represent various structural health conditions are extracted from the simulation dataset using vehicle-track coupled dynamics. By integrating these semantic features with real-world healthy data through domain adaptation and contrastive learning techniques, the proposed method is capable of effectively detecting failures in previously unseen practical scenarios. The results demonstrate that SSFZSDA achieves 99.7% accuracy in detecting three distinct levels of fastener loosening based on track acceleration data, while also demonstrating excellent performance based on vehicle-mounted acceleration data, achieving 92% identification accuracy. The proposed method’s effectiveness and generalization are validated through comparative analysis, outperforming other state-of-the-art zero-shot domain adaptation methods.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110186"},"PeriodicalIF":5.7,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266199","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}
引用次数: 0
Wear degradation analysis of pick against conglomerate under thermo-mechanical coupling 热-力耦合作用下镐对砾岩磨损退化分析
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-03 DOI: 10.1016/j.engfailanal.2025.110183
Yanqing Yu , Tianbing Ma , Chen Shen , Ce Bian , Rui Shi , Changpeng Li , Qinghui Shi
{"title":"Wear degradation analysis of pick against conglomerate under thermo-mechanical coupling","authors":"Yanqing Yu ,&nbsp;Tianbing Ma ,&nbsp;Chen Shen ,&nbsp;Ce Bian ,&nbsp;Rui Shi ,&nbsp;Changpeng Li ,&nbsp;Qinghui Shi","doi":"10.1016/j.engfailanal.2025.110183","DOIUrl":"10.1016/j.engfailanal.2025.110183","url":null,"abstract":"<div><div>To clarify the hard rock breaking wear degradation mechanism of the pick, a full-cycle wear test of the pick from the original stage to complete failure was conducted using a home-made pick wear tester. The thermo-mechanical coupling degradation behavior of the pick during the rock-breaking process was analyzed by monitoring the wear mass, overall morphology, vibration acceleration, and thermogram. In addition, rock debris, wear nephogram, and microscopic wear morphology were observed to further reveal the wear mechanism of the pick. Results indicate that the pick experiences four stages before complete failure: (Ⅰ) self-sharpening, (Ⅱ) pick body thinning, (Ⅲ) pick tip detachment, and (Ⅳ) severe pick body wear. The mass wear rate and temperature rise of the pick in stages Ⅰ and Ⅳ are higher than those in stages Ⅱ and Ⅲ. Besides, the waveform and zero-crossing rate (ZCR) of vibration acceleration change in stage Ⅲ. Therefore, temperature and vibration acceleration can be used as a judgment for pick failure. The dominant wear mechanism of the pick tip is impact wear, but the volume loss is low due to its high hardness. The wear mechanism of the pick body changes to abrasive and oxidative wear. The rock debris plays various roles in different regions and stages. High temperature will cause the pick body matrix to soften and promote the rock debris action.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110183"},"PeriodicalIF":5.7,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266471","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}
引用次数: 0
A metallurgical failure analysis of mTBM disc cutters under hard rock excavation mTBM盘式切割机在硬岩开挖下的冶金失效分析
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-03 DOI: 10.1016/j.engfailanal.2025.110184
Gabriela R. Piazzetta , Heloísa C. Moreira , Julio C.K. das Neves , Cássio S.N. Penteado , Giuseppe Pintaude
{"title":"A metallurgical failure analysis of mTBM disc cutters under hard rock excavation","authors":"Gabriela R. Piazzetta ,&nbsp;Heloísa C. Moreira ,&nbsp;Julio C.K. das Neves ,&nbsp;Cássio S.N. Penteado ,&nbsp;Giuseppe Pintaude","doi":"10.1016/j.engfailanal.2025.110184","DOIUrl":"10.1016/j.engfailanal.2025.110184","url":null,"abstract":"<div><div>Predicting wear in Tunnel Boring Machine (TBM) disc cutters remains a complex challenge due to extreme operational conditions and numerous variables involved in hard rock excavation. This study comprehensively investigates the failure modes and wear mechanisms of mTBM disc cutters, aiming to refine existing wear classifications and improve understanding of the degradation processes. Through a multi-scale approach combining macroscopic visual inspection, optical microscopy (OM), scanning electron microscopy (SEM), microhardness profiling, and X-Ray diffraction (XRD), twelve worn disc cutters from an urban sanitation tunnel were analyzed. Our findings reveal normal/sharpening wear as the most prevalent (58 %), followed by blockage (25 %) and mushrooming (17 %), with distinct distributions based on cutter position. Crucially, microscopic analysis identified the systematic formation of White Etching Layers (WLs) and Dark Layers (DLs) on worn surfaces, where the WL exhibits increased hardness, grain refinement, and a higher content of retained austenite compared to the substrate. Crack nucleation was predominantly observed at the WL/DL interface, a zone of pronounced mechanical property mismatch, leading to progressive material chipping. This observation, supported by detailed microstructural evidence, challenges previous interpretations that dismiss sliding contact in field conditions, strongly suggesting a hybrid rolling-sliding contact mode at the rock-cutter interface. The study underscores the critical role of these subsurface microstructural changes in cutter degradation, advocating for a refined wear classification that incorporates these mechanisms. These insights are vital for optimizing TBM cutter design and enhancing durability under severe excavation conditions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110184"},"PeriodicalIF":5.7,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145265576","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}
引用次数: 0
Fracture behavior in tensile and fatigue tests of diffusion bonded TC4 titanium alloy at room and high temperatures 扩散焊TC4钛合金室温和高温拉伸疲劳断裂行为
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-01 DOI: 10.1016/j.engfailanal.2025.110182
Can Li , Dexin Zhang , Xiaoxing Li , Yingjian Guo , Yong Li
{"title":"Fracture behavior in tensile and fatigue tests of diffusion bonded TC4 titanium alloy at room and high temperatures","authors":"Can Li ,&nbsp;Dexin Zhang ,&nbsp;Xiaoxing Li ,&nbsp;Yingjian Guo ,&nbsp;Yong Li","doi":"10.1016/j.engfailanal.2025.110182","DOIUrl":"10.1016/j.engfailanal.2025.110182","url":null,"abstract":"<div><div>The synergistic effects of matrix microstructure and bonding interface characteristics on the tensile and fatigue properties of the diffusion bonded (DB) TC4 titanium alloy at room temperature and 400℃ were studied. A double-stage heat treatment with various cooling conditions (750-850℃) was performed on the DB joints due to the precision manufacturing requirements of the fan blade. Matrix microstructure evolution caused significant tensile strength and fatigue life degradation of the DB joint at room temperature. At 400 °C, all tensile specimens exhibited ductile fracture morphology, with tensile strength showing negligible dependence on interface or matrix microstructure evolution. However, the influence of matrix microstructure and DB interface on fatigue performance at 400℃ was strongly related to the load conditions. During fatigue testing at 400℃ and 315 MPa (50 % of the tensile strength), the petal-like α + β colonies with a volume fraction of 10.5 % inhibited the crack propagation of the DB joint. Conversely, the preferentially oriented β grains with the &lt; 111 &gt; slip direction aligned parallel to the fatigue loading direction, along with lath α + β colonies exhibiting a 21.5 % volume fraction, facilitated crack initiation and propagation. Notably, when fatigue cracks extended into the weakly bonded region at the DB interface, crack propagation was impeded, accompanied by a shrinkage of the plastic zone at the crack tip. Under higher fatigue loads (70 % of the tensile strength), crack propagation was accelerated at the micro-pores of the DB interface, irrespective of testing temperature (room temperature or 400 °C). The fracture surfaces exhibited minimal plastic strain, resulting in negligible differences in fatigue life between the two heat-treated DB joints with distinct α + β colony microstructures.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110182"},"PeriodicalIF":5.7,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266203","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}
引用次数: 0
Fatigue failure analysis and life prediction of forged 6061 aluminum alloy wheel hubs based on precipitate size effects and multiaxial stress modeling 基于析出相尺寸效应和多轴应力模型的锻造6061铝合金轮毂疲劳失效分析与寿命预测
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-10-01 DOI: 10.1016/j.engfailanal.2025.110181
Haijin Yang , Yuxin Cui , Fangcheng Qin , Tao Lin , Yuying Zheng
{"title":"Fatigue failure analysis and life prediction of forged 6061 aluminum alloy wheel hubs based on precipitate size effects and multiaxial stress modeling","authors":"Haijin Yang ,&nbsp;Yuxin Cui ,&nbsp;Fangcheng Qin ,&nbsp;Tao Lin ,&nbsp;Yuying Zheng","doi":"10.1016/j.engfailanal.2025.110181","DOIUrl":"10.1016/j.engfailanal.2025.110181","url":null,"abstract":"<div><div>Forged aluminum alloy wheel hubs are susceptible to premature fatigue failure under multiaxial loading in automotive applications. This study aims to address these challenges by developing a fatigue life prediction model that incorporates the crack initiation mechanisms specific to forged 6061 aluminum alloy. The microstructure and mechanical properties of the material were thoroughly characterized, revealing that cracks typically initiate at surface defects and precipitate-matrix interfaces. The grain sizes are refined to 50–100 μm, and a uniform precipitate distribution is obtained by dynamic recrystallization during the spinning process, thereby enhancing the strength–ductility synergy. Fractographic analysis revealed crack initiation at surface defects or precipitate–matrix interfaces. A three-stage failure mechanism “precipitate size–interfacial stress–microvoid evolution” is proposed: (I) stress concentration caused by precipitates exceeding the critical size, (Ⅱ) debonding driven by interfacial stress, and (Ⅲ) crack nucleation induced by microvoid evolution. To improve the accuracy of fatigue life predictions, a modified Basquin equation is combined with the critical plane method, integrating a fatigue stress concentration index (FSCI) and a life sensitivity coefficient (<em>η</em> = 0.085). The model demonstrates high predictive accuracy, with a maximum deviation of −1.8 % and an average error of less than 2 % compared to simulation results. The FSCI-based model gives a reliable prediction on the fatigue life exceeding 10<sup>7</sup> cycles at operational stress amplitude below 140 MPa.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110181"},"PeriodicalIF":5.7,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145265525","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}
引用次数: 0
A prediction model for dyke-dam piping based on data augmentation and interpretable ensemble learning 基于数据增强和可解释集成学习的堤坝管道预测模型
IF 5.7 2区 工程技术
Engineering Failure Analysis Pub Date : 2025-09-30 DOI: 10.1016/j.engfailanal.2025.110174
Xi Zhang , Yangyang Xia , Chao Zhang , Bokai Liu , Cuixia Wang , Hongyuan Fang , Jing Wang
{"title":"A prediction model for dyke-dam piping based on data augmentation and interpretable ensemble learning","authors":"Xi Zhang ,&nbsp;Yangyang Xia ,&nbsp;Chao Zhang ,&nbsp;Bokai Liu ,&nbsp;Cuixia Wang ,&nbsp;Hongyuan Fang ,&nbsp;Jing Wang","doi":"10.1016/j.engfailanal.2025.110174","DOIUrl":"10.1016/j.engfailanal.2025.110174","url":null,"abstract":"<div><div>Piping is one of the most common and hazardous issue in dyke and dam engineering, posing challenges for dyke and dam stability and risk assessments. In this study, an interpretable ensemble learning prediction model of dyke and dam piping was proposed based on the Synthetic Minority Over-sampling Technique (SMOTE) method and Ensemble Learning (EL) algorithm with a dataset collected from Yangtze River. Initially, the piping dataset was visualized using the violin diagram, and the SMOTE method was adopted to augment the imbalanced dataset. Then, t-distributed Stochastic Neighbor Embedding (t-SEN) method and Pearson correlation coefficient were used to consider the similarity between the newly generated samples and the original samples, which verify the effectiveness of the data augmentation. Subsequently, based on the augmented dataset, six EL algorithms were employed to establish the regression prediction model of piping. Through comprehensive comparison, the SMOTE-Categorical Boosting (SMOTE-CatBoost) model exhibits superior prediction accuracy and lower calculation cost, with a goodness of fit (R<sup>2</sup>) of 0.9886 and a Root Mean Square Error (RMSE) of 0.05334, making it the ideal prediction model for dyke and dam piping. Additionally, an Explainable Artificial Intelligence (XAI) model of<!--> <!-->piping was developed, and it was found that the thickness of overburden thickness of weak permeable layer (<span><math><mrow><mi>H</mi></mrow></math></span>), void ratio (<span><math><mrow><mi>e</mi></mrow></math></span>), water level height difference (<span><math><mrow><mi>Δ</mi><mrow><mi>h</mi></mrow></mrow></math></span>), and compression coefficient (<span><math><mrow><msub><mrow><mi>a</mi></mrow><mrow><mi>v</mi></mrow></msub></mrow></math></span>) are the four primary influencing factors of piping. The research offers valuable reference for the advance monitoring of dyke and dam piping risk, and contributes to the sustainable maintenance of dyke and dam engineering structures.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110174"},"PeriodicalIF":5.7,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216624","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}
引用次数: 0
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