Engineering Failure Analysis最新文献

{"title":"Research on fatigue crack propagation behavior and fatigue life of AA2524 sheet after laser heating − Laser shot peening","authors":"Songbai Li,&nbsp;Peijun Li,&nbsp;Qiyun Zhu,&nbsp;Mei Yin,&nbsp;Xinhua Zhu,&nbsp;Hui Long","doi":"10.1016/j.engfailanal.2025.109760","DOIUrl":"10.1016/j.engfailanal.2025.109760","url":null,"abstract":"<div><div>In order to prolong the service life of AA2524 panel, a composite process of laser heating(LH) and laser shot peening(LSP) was proposed to modify the surface of AA2524 panel. The compressive residual stress(CRS) on the panel surface was induced to delay the fatigue crack growth rate(FCGR) and prolong the service life. A single LH-LSP was performed on the AA2524 specimen. The surface residual stress and surface hardness of specimen were measured, the FCGR of specimen was evaluated under different stress ratios, and the microstructure of the fatigue fracture of specimen was observed. The fatigue life of the specimen was predicted by weight function combined with fatigue crack growth rate formula. The results show that compared with specimen after single LH and single LSP, specimen after single LH-LSP can induce greater surface CRS, and has the best life prolonging effect. When <em>R</em> = 0.1, the FCGR of the specimen after composite process is about 31.2 % lower than that of the base material specimen. The root-mean-square error(RMSE) (3.83 %) of fatigue life prediction by Wu + Walker model is smaller than that by Wu + Forman model (5.72 %) and Wu + Elber model (7.68 %). The composite process can better prolong the life of aviation AA2524 panel.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109760"},"PeriodicalIF":4.4,"publicationDate":"2025-05-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167383","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":"Fracture mechanism and life prediction of IN718 under very high cycle variable amplitude loading at high temperature","authors":"Zeshuai Shen,&nbsp;Zhiyong Huang,&nbsp;Jian Wang,&nbsp;Hongjiang Qian,&nbsp;Liangqi Zheng,&nbsp;Qikai Zhou,&nbsp;Qingyun Zhu,&nbsp;Jiebin Shen","doi":"10.1016/j.engfailanal.2025.109745","DOIUrl":"10.1016/j.engfailanal.2025.109745","url":null,"abstract":"<div><div>This study investigates the effect of variable amplitude loading on the very high cycle fatigue (VHCF) behavior of IN718 superalloy at high temperature. VHCF tests are conducted on IN718 superalloy at 650 °C under low-to-high stress amplitude (<em>σ_L/H</em>) and high-to-low stress amplitude (<em>σ_H/L</em>) conditions. The <em>σ_L/H</em> mode and <em>σ_H/L</em> mode show an increasing trend and a decreasing trend in fatigue life, respectively. Through the analysis of fracture surface morphology and microstructural characteristics along cracks, in crack initiation region, cracks are found to tend to initiate around carbides for both modes while enhanced dislocation slip activity caused by high stress amplitude in the <em>σ_H/L</em> mode is the main reason for shortened fatigue life. In crack tip region, for <em>σ_H/L</em> mode, crack is found to tend to propagate between grains with small twist angle (<em>α</em>) and tilt angle (<em>β</em>) and grains with low Schmid factors show high resistance to crack propagation while disordered microstructures are observed for <em>σ_L/H</em> mode. To further realize life prediction, a model based on CatBoost algorithm is established and outperforms empirical equation with the error decreasing by nearly 50 %.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"178 ","pages":"Article 109745"},"PeriodicalIF":4.4,"publicationDate":"2025-05-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144148104","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 investigation of hybrid double-lap shear bolted connections with additively manufactured 316L stainless steel inner plates","authors":"Hasan Almuhanna ,&nbsp;Giacomo Torelli ,&nbsp;Renan Kindermann ,&nbsp;Luca Susmel","doi":"10.1016/j.engfailanal.2025.109756","DOIUrl":"10.1016/j.engfailanal.2025.109756","url":null,"abstract":"<div><div>The growing body of research on additive-manufactured components in structural engineering highlights the importance of assessing their potential, particularly in understanding how key manufacturing and design parameters influence performance. In this context, alongside conventional inner plates, this study investigates the failure behaviour of additive-manufactured inner plates of 316L stainless steel as hybrid component in double-lap shear bolted configurations. Two distinct printing methods were considered: wire arc additive manufacturing and selective laser melting. The study considered different surface conditions (as-built and machined) and extraction/print direction <span><math><mo>(</mo><mi>θ</mi><mo>=</mo><msup><mn>0</mn><mo>°</mo></msup><mo>,</mo><mspace></mspace><msup><mn>45</mn><mo>°</mo></msup><mo>,</mo><mspace></mspace><mspace></mspace><msup><mn>60</mn><mo>°</mo></msup><mspace></mspace><mi>a</mi><mi>n</mi><mi>d</mi><mspace></mspace><msup><mn>90</mn><mo>°</mo></msup><mo>)</mo></math></span>. By evaluating the actual failure mode and cracking behaviour, this study explores the influence of the manufacturing process and variations in geometrical design parameters, treated as key variables affecting the failure mechanism of the inner plates. The findings indicate that while the test coupons exhibited significant variations in stiffness and ductility, the failure behaviour of conventional and additively manufactured inner plates remained largely similar when accounting for surface condition and printing direction. Differences in load capacity across manufacturing methods were found to be limited when thickness was controlled. However, distinctly different crack propagation paths were observed in as-built wire arc additive-manufactured inner plates extracted at <span><math><mi>θ</mi><mo>=</mo><msup><mn>45</mn><mo>°</mo></msup></math></span> and <span><math><msup><mn>60</mn><mo>°</mo></msup></math></span>, attributed to the effect of diagonal printing layers. These insights contribute to understanding overall connection integrity and highlight both the challenges and opportunities of integrating additive manufacturing into bolted connections.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109756"},"PeriodicalIF":4.4,"publicationDate":"2025-05-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167382","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":"Splits in metallic materials: A critical review","authors":"Sergio Luis Gonzalez Assias ,&nbsp;Hector Guillermo Kotik ,&nbsp;Juan Elías Perez Ipiña","doi":"10.1016/j.engfailanal.2025.109747","DOIUrl":"10.1016/j.engfailanal.2025.109747","url":null,"abstract":"<div><div>Splits are delaminations that can occur in metallic alloys during mechanical laboratory testing or under operational conditions in real-world structures. This review provides a comprehensive overview, analysis, and discussion of key contributions to the understanding of split phenomena in metallic alloys, addressing well-established concepts, contextualizing recent developments, and highlighting unresolved questions surrounding this phenomenon.</div><div>The review begins by introducing the use of the term “delamination” in materials science and engineering. Subsequently, the classification of delamination types is explored. While the primary focus of this critical review is on splits, certain aspects of other types of delaminations are also briefly discussed. Emphasis is placed on the occurrence of splits in pipeline materials, given the significant impact of this phenomenon. The factors contributing to delamination events in metallic materials with current and potential applications in critical industries are examined in detail. Furthermore, the interpretation of delamination events in the mechanical behavior of metals is thoroughly analyzed through various mechanical tests, including tensile tests, Charpy-V notch tests, drop-weight tear tests, and fracture toughness tests, with a special focus on their implications for structural integrity.</div><div>Morphological and geometric characteristics of splits in fracture mechanics specimens are reviewed by analyzing recently published tomography results. The phenomenon of split toughening, and delamination toughening more broadly, is explained, and recent trends in leveraging split toughening to design and produce metallic alloys with superior strength and toughness are contextualized. Finally, the role of split events in hydrogen embrittlement is discussed, highlighting contradictory interpretations of splits in this context.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109747"},"PeriodicalIF":4.4,"publicationDate":"2025-05-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167384","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":"Effect of decarburization-induced abnormal grain growth on the formation of cracks in ASTM A335 grade P11 low alloy steel seamless pipes","authors":"Dhanendra Kumar Sahu ,&nbsp;Nilesh Suryawanshi ,&nbsp;Dhananjay Bajpeyee ,&nbsp;M.J.N.V. Prasad","doi":"10.1016/j.engfailanal.2025.109755","DOIUrl":"10.1016/j.engfailanal.2025.109755","url":null,"abstract":"<div><div>The present study investigated the cause of the frequent failures of the hot-pierced and stretch-rolled low alloy ASTM A335 Grade P11 low alloy steel pipes consisting of ferrite and pearlite microstructure. A detailed microstructural examination that includes optical microscopy and scanning electron microscopy in conjunction with electron back-scattered diffraction (EBSD) and energy dispersive spectroscopy (EDS) was performed across the thickness of the failed and sound pipe samples. Microhardness measurements were performed to evaluate the microstructural inhomogeneity, if any across the thickness of the failed and sound pipe samples. It has been noticed that the substantial fraction of abnormally grown ferrite grains in thick decarburized layers, being softer in nature, could not resist the applied pressures and thereby resulted in easy cracking under tensile loading condition thus leading to the failure of the steel pipes during subsequent hydro-pressure testing or in application.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"178 ","pages":"Article 109755"},"PeriodicalIF":4.4,"publicationDate":"2025-05-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144137894","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":"Analysis of failure mechanisms for CFRP laminated composite bogie frames of the next generation high-speed trains under service environment","authors":"Yating Han ,&nbsp;Ruichen Wang ,&nbsp;Paul Allen ,&nbsp;David Crosbee ,&nbsp;Wenjie Feng","doi":"10.1016/j.engfailanal.2025.109701","DOIUrl":"10.1016/j.engfailanal.2025.109701","url":null,"abstract":"<div><div>Carbon fiber reinforced polymer (CFRP) laminated composites are gradually adopted in next-generation high-speed train bogie frames due to their superior mechanical properties. However, the failure behavior of CFRP structures under service conditions remains insufficiently understood. To address this, a progressive fatigue damage method based on element-level analysis is employed and integrated into a novel rigid–flexible coupled high-speed train model incorporating CFRP laminated bogie frames. In particular, the model established here enables real-time updates of material stiffness, strength, and governing equations in the degradation progresses based on the finite element method (FEM) and the floating frame of reference, making it particularly well-suited for analyzing the failure behavior of CFRP laminated bogie frame under service conditions. Numerical results indicate that under the excitation of track irregularity, there are three main failure modes of the bogie frame during high-speed train operation (running 100 kilometers on a straight track with a constant speed 300 km/h), i.e., matrix tensile failure (FM3), matrix compression failure (FM4), and tensile delamination (FM5). Specifically, FM3 occurs when the <span><math><msub><mrow><mi>E</mi></mrow><mrow><mn>12</mn></mrow></msub></math></span> is reduced by approximately 46%–48%, FM4 is triggered with a 21%–23% reduction in <span><math><msub><mrow><mi>E</mi></mrow><mrow><mn>12</mn></mrow></msub></math></span>, and FM5 is associated with a reduction of interlaminar tensile strength (<span><math><msub><mrow><mi>S</mi></mrow><mrow><mn>3</mn><mi>t</mi></mrow></msub></math></span>) by about 85%–87%. These findings may offer practical design guidance. Among others, symmetric ±45°ply orientations should be incorporated in shear-critical regions, such as the curved areas of the side beam, to enhance shear stiffness and delay matrix-dominated failure. Additionally, localized reinforcements, such as applying interlayer resin near the suspension areas, can help mitigate delamination risk. The numerical strategy provides a robust foundation for fatigue prediction, optimization, and the development of damage-tolerant designs for CFRP bogie frames in high-speed rail applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"178 ","pages":"Article 109701"},"PeriodicalIF":4.4,"publicationDate":"2025-05-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144130793","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":"Hydrogen charging-induced corrosion behavior evolution of an additive-manufactured austenitic stainless steel in sulfuric acid medium","authors":"Qiancheng Zhao ,&nbsp;Hong Luo ,&nbsp;Chengtao Li ,&nbsp;Bingbing Yan ,&nbsp;Guangxue Liang","doi":"10.1016/j.engfailanal.2025.109753","DOIUrl":"10.1016/j.engfailanal.2025.109753","url":null,"abstract":"<div><div>The corrosion behavior of additive-manufactured UNS S21900 steel in 0.5 M H₂SO₄ was studied after hydrogen charging. The results indicated the decreased corrosion resistance after hydrogen charging. Passive current density increased from 2.95 × 10^-6 to 2.01 × 10^-5 A·cm⁻² after 12 h, accompanied by inductive behavior. Mott-Schottky analyses showed increased acceptor density (2.67 × 10²² to 5.83 × 10²² cm⁻³) and donor density (1.91 × 10²¹ to 2.74 × 10²¹ cm⁻³) after charging for 12 h. The O^2–/OH^– ratio dropped from 2.25 to 0.05 after 12 h charging, indicating reduced compactness and protection due to the increased presence of metal hydroxides.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"178 ","pages":"Article 109753"},"PeriodicalIF":4.4,"publicationDate":"2025-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144137891","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 its effect on the fatigue life of receding grooves in 300 M steel bolt under the surface rolling process","authors":"Hongwei Liu ,&nbsp;Renke Kang ,&nbsp;Zhigang Dong ,&nbsp;Xianglong Zhu ,&nbsp;Haotian Mu ,&nbsp;Kanghua Huang","doi":"10.1016/j.engfailanal.2025.109752","DOIUrl":"10.1016/j.engfailanal.2025.109752","url":null,"abstract":"<div><div>Ultra-high strength steel bolts are high-performance fasteners used in aerospace applications. Due to prolonged exposure to high loads and impacts, bolts are susceptible to fatigue failure, with fatigue fracture at the receding groove being one of the primary failure modes. In this work, surface rolling process (SRP) with varying rolling force is applied to treat receding groove of 300 M steel bolt. A comparative analysis is conducted on surface geometric state, microstructure, and residual stresses, and their influence mechanism on fatigue life are discussed. After SRP, the surface roughness of bolt receding groove is decreased, and the gradient microstructure and compressive residual stress (CRS) field are induced. At a rolling force of 380 N, the surface integrity of bolt sample is comprehensively improved, causing an 8.45-fold enhancement in fatigue life compared to the BM sample. All surface integrity factors have their own contributions in improving fatigue life, the moderately refined gradient microstructure and high amplitude CRS field are the primary factors for enhancing fatigue life, with high amplitude CRS field being more critical. However, synergistic improvements in surface integrity cannot be ignored, and the mechanism of SRP for improving the fatigue life is the synergistic effect of high amplitude CRS field, excellent surface geometric state and fine gradient microstructure.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109752"},"PeriodicalIF":4.4,"publicationDate":"2025-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144185412","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":"Compressive behavior and models of FRP-confined coal gangue concrete after sulfate exposure and sustained high stress conditions","authors":"Linli Yu,&nbsp;Hai Pu,&nbsp;Junwu Xia,&nbsp;Kangsheng Xue,&nbsp;Ming Li","doi":"10.1016/j.engfailanal.2025.109750","DOIUrl":"10.1016/j.engfailanal.2025.109750","url":null,"abstract":"<div><div>With advancements in fiber-reinforced polymer (FRP), FRP-confined coal gangue concrete (FCGC) has been explored as a potential supporting member for underground mines. Nevertheless, supporting structures face harsh conditions, including sulfate exposure and sustained load, which can severely impact the compressive performance of FCGC. Thus, the axial compressive test was performed on FCGC after sulfate exposure and sustained high stress conditions, taking inner concrete, FRP layer, stress-to-strength ratio, sulfate concentration and load duration time as variables. Results indicate that after sulfate exposure and sustained high stress conditions, the failure modes of FCGC also feature the FRP hoop rupture near the mid-height region, and the stress–strain curves also display a bilinear pattern, compared to the control specimens. The slope of the initial portion shows a slight increase due to the compactness of the inner concrete, while the second portion exhibits a degradation. The residual ratio of ultimate stress and strain ranges from 0.897–1.062, and 0.633–0.805, respectively, where the extent of degradation increases with higher sulfate concentration and stress-to-strength ratios. Besides, after sulfate exposure and sustained high stress conditions, the lateral strain of FCGC becomes larger if the axial strain is the same. Furthermore, the strength and strain models were modified incorporating the impact factors of load duration time, sulfate concentration, and stress-to-strength ratio.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"179 ","pages":"Article 109750"},"PeriodicalIF":4.4,"publicationDate":"2025-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167381","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 of sulfur transport jacketed pipeline induced by the combined effects of steam erosion and wet sulfur corrosion","authors":"Jingjing Jiang ,&nbsp;Lihua Huang ,&nbsp;Zicheng Peng ,&nbsp;Jing Yan ,&nbsp;Ganghua Huang ,&nbsp;Yongfan Tang","doi":"10.1016/j.engfailanal.2025.109749","DOIUrl":"10.1016/j.engfailanal.2025.109749","url":null,"abstract":"<div><div>Double-layer jacketed pipelines are crucial for the economical, efficient, and safe transportation of sulfur in natural gas purification plants. However, several plants in the Sichuan and Chongqing regions have faced perforation and leakage issues with their liquid sulfur jacketed pipelines during routine operations, hindering long-term stable operation. Taking a specific purification plant as a case study, a comprehensive failure analysis was conducted on its jacketed pipeline, which had been in operation for less than two years. Techniques such as physical and chemical property analysis, XRD, XPS, SEM, EDS, and metallographic examination were employed. The analysis showed that the pipeline’s chemical composition met the standard requirements, its microstructure was normal, and material quality was satisfactory. Corrosion morphology and product analysis revealed internal-to-external corrosion perforation. Considering the actual operating conditions, it was hypothesized that corrosion and impact stress on the inner and outer walls of the pipeline in the liquid sulfur, sulfur vapor, and water vapor environment led to the formation of a weak zone. Based on these findings, design optimization and process parameter adjustments are recommended to enhance the safe operation and management of such pipelines.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"178 ","pages":"Article 109749"},"PeriodicalIF":4.4,"publicationDate":"2025-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167225","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}