Engineering Failure Analysis最新文献

{"title":"Process-induced defects and failure mechanisms in metal additive manufacturing: A mesoscale coupled damage and plasticity modeling and X-ray computed tomography approach","authors":"Jairan Nafar Dastgerdi ,&nbsp;Milad Lotf Yasouri ,&nbsp;Heikki Remes","doi":"10.1016/j.engfailanal.2024.109123","DOIUrl":"10.1016/j.engfailanal.2024.109123","url":null,"abstract":"<div><div>This study aims to clarify the effect of process-induced defects on the damage behavior of metal additive manufactured (AM) components at the mesoscale using a numerical approach based on the coupled continuum damage mechanics (CDM) and plasticity model to provide a guideline for assessing the strength of metal AM components by considering defects’ features and their interaction. For this purpose, the finite element (FE) simulations, instantiated from the real microstructures captured by the initial X-ray computed tomography (XCT) imaging from the intact sample at several locations around the specimen, are deployed to reveal the activity of multiple failure mechanisms. FE simulations precisely identify the sites and the mechanism of ductile failure compared to experimentally observed sites of damage initiation and evolution based on XCT imaging in a temporal domain during tensile loading for the AM 316L stainless steel sample. It is found that the intervoid necking mechanism mainly controls the interaction of internal and surface defects and internal defects in close proximity. Then, the other intervoid sheeting and intervoid shearing mechanisms are active sequentially during the failure process. A systematic investigation is carried out to first reveal the defect-property relationships in damage progression and deformation patterns of these materials and then to define acceptance limits for internal and surface defects’ shape, size, distribution, and proximity to each other, identifying when the imperfections become defects. The results of this study can pave the road to overcoming the limitation of more widespread use of metal AM materials in different industries by providing a validated numerical approach to optimizing process parameters based on understanding the interaction between different process parameters, resultant internal and surface defects, and damage behavior of these materials under service loading.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109123"},"PeriodicalIF":4.4,"publicationDate":"2024-11-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142747651","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":"Phase field modelling of tunnel excavation damage in transversely isotropic rocks","authors":"Zijun Lan ,&nbsp;Weizhong Chen ,&nbsp;Jingqiang Yuan ,&nbsp;Mengzhe Huo ,&nbsp;Kai Shen","doi":"10.1016/j.engfailanal.2024.109113","DOIUrl":"10.1016/j.engfailanal.2024.109113","url":null,"abstract":"<div><div>Layered rocks, prevalent in geological formations, exhibit complex failure behaviours driven by pronounced anisotropy in their mechanical properties. However, the intricate failure mechanisms remain inadequately understood due to the spatial complexity of these mechanical responses. To address this challenge, this study proposes a novel phase field model tailored for layered rocks. A new strain energy decomposition method is introduced, uniquely formulated based on stress components and designed for transversely isotropic constitutive models. Numerical solutions to the coupled stress-phase field equations are obtained using user-defined element and material subroutines, implemented through a staggered solution scheme. The accuracy and robustness of the numerical approach are validated through simulations of a composite panel with a central hole under tensile loading. Additionally, the model is applied to the excavation of the layered soft rock tunnel, revealing the significant influence of bedding plane angles on displacement and stress field distributions, as well as post-excavation failure modes. Notably, the model captures the predominant shear-slip failure along bedding planes following excavation, effectively reflecting the complex mechanical interactions in layered rocks. This proposed model represents a significant advancement in understanding the failure mechanisms of layered rocks, providing a valuable tool for future geotechnical applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109113"},"PeriodicalIF":4.4,"publicationDate":"2024-11-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142747652","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":"Crystallographic changes and mechanical Performances of SnAg2.4/Cu Pillars during thermal shocks in a large temperature range","authors":"Xiangyu Chen ,&nbsp;Xinyi Jing ,&nbsp;Keyu Luo ,&nbsp;Liqiang Cao ,&nbsp;Peng He ,&nbsp;Shuye Zhang","doi":"10.1016/j.engfailanal.2024.109125","DOIUrl":"10.1016/j.engfailanal.2024.109125","url":null,"abstract":"<div><div>Microelectronics can easily be destroyed under extreme temperature conditions. Smaller solder joints become the weak points and enhance the risk of microelectronics failures. Therefore, it is essential to study the reliability of high-density packaged micro-bumps under extreme temperature conditions. This study investigated the impact of thermal shock on micro-bumps reliability, focusing on the microstructural and crystalline changes at the interface. Additionally, ball shear tests were conducted to evaluate the mechanical properties and fracture behavior of the micro-bumps. The results indicated that with increasing thermal shock cycles, the Cu₃Sn thickness steadily increases, twins appeared in the Sn after 200 cycles, and the grain orientation was about 60°, with the primary twin system being {111} &lt; 010&gt;; furthermore, stress-induced led to grain orientation alignment and an increase in grain size, while the shear mechanical properties, microhardness, and modulus of micro-bumps decrease with the increasing number of thermal shock cycles.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109125"},"PeriodicalIF":4.4,"publicationDate":"2024-11-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142746952","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on failure mechanism and seismic performance of RC Frame-Infilled walls structures reinforced by CFRP","authors":"Xuetan Zhang,&nbsp;Yang Zhou,&nbsp;Xiangyu Liu,&nbsp;Changda Wang,&nbsp;Zhiguo Sun","doi":"10.1016/j.engfailanal.2024.109114","DOIUrl":"10.1016/j.engfailanal.2024.109114","url":null,"abstract":"<div><div>The reinforced concrete (RC) frame structure with continuous half-height infilled walls is a common structural form. However, the existence of infilled walls alters the structure’s force mechanism and failure mode, making the frame columns susceptible to brittle failure and adversely affecting the overall seismic performance. To enhance the seismic capacity of such systems, quasi-static tests were conducted on RC frame-infilled wall models reinforced with different CFRP methods. Based on the test results, numerical analysis models of RC frame-infilled walls were established to perform parametric studies and quantitatively assess the impact of various CFRP reinforcement methods on seismic performance. The results indicate that both full wrapping and strip reinforcement methods can improve the failure mode and enhance the seismic capacity of the frame-infilled wall structure, but the degree of improvement varies significantly. Compared to the unreinforced frame, the ductility, ultimate bearing capacity, initial stiffness, and energy dissipation of the fully wrapped and strip-reinforced frames increased by 42.86% and 58.76%, 30.43% and 10.65%, 68.76% and 9.55%, 298.01% and 340.92%, respectively. Considering the overall seismic demand and CFRP utilization rate, the strip reinforcement method is more suitable for the seismic strengthening of half-height infilled wall frame structures. When using the same amount of CFRP without other improvement measures, it is recommended that the ratio of strip spacing to strip width be between 1.1 and 1.25.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109114"},"PeriodicalIF":4.4,"publicationDate":"2024-11-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705821","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":"Numerical investigation on bending characteristic and ductile fracture of AA7075 thin-walled beam using advanced orthotropic plasticity and fracture models","authors":"Tianyu Xu ,&nbsp;Duquan Zuo ,&nbsp;Ti Ye ,&nbsp;Guohao Zhang ,&nbsp;Yufeng Zhang","doi":"10.1016/j.engfailanal.2024.109122","DOIUrl":"10.1016/j.engfailanal.2024.109122","url":null,"abstract":"<div><div>Thin-walled structures manufactured from the 7075 aluminum alloy are gaining tremendous attention in the automotive industry for their potential to reduce vehicle weight. However, the bending characteristics and rupture behavior of the AA7075 thin-walled beams under unexpected collision events have not been extensively studied. This study aims to fill that gap through a detailed numerical investigation of the bending deformation and failure mechanism of AA7075 thin-walled beams under quasi-static three-point bending at room temperature. Full-size, three-dimensional numerical simulations of laboratory-scale AA7075-T6 hat-shaped beam were conducted using the ABAQUS/Explicit solver. The material elastic–plastic response is described by a rate-independent constitutive description, incorporating advanced non-quadratic orthotropic plasticity and anisotropic ductile fracture criteria via VUMAT subroutines. Results indicate that the simulations accurately reproduced experimental observations, including the loading-displacement curves and deformation patterns. The bending behavior of the AA7075-T6 thin-walled beams aligns with typical bending collapse mechanisms, consistent with Kecman’s theory. The rupture process exhibits ductile fracture characteristics, with heterogeneous stress distribution across the material thickness affecting crack initiation rates between the upper and lower surfaces. Notably, the stress state at the fracture’s half-thickness section approximates an equi-biaxial tension condition. These findings provide essential insights into the bending deformation and failure mechanisms of AA7075 thin-walled structures under unexpected impact loading.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109122"},"PeriodicalIF":4.4,"publicationDate":"2024-11-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142720568","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":"Low-cycle fatigue behavior of U71Mn rail steel with pre-corrosion","authors":"Zhenghong Fu ,&nbsp;Yunlai Sun ,&nbsp;Yanan Hu ,&nbsp;Rong Chen ,&nbsp;Ping Wang ,&nbsp;Qianhua Kan","doi":"10.1016/j.engfailanal.2024.109118","DOIUrl":"10.1016/j.engfailanal.2024.109118","url":null,"abstract":"<div><div>Rail steels that are extensively exposed to the humid natural environment increasingly experience corrosion fatigue, emerging as a potential and hazardous failure mode. This work investigates the low-cycle fatigue behavior of pre-corrosion U71Mn rail steel. The corrosion features, cyclic stress–strain response, fatigue life, and underlying mechanisms are systematically analyzed. The results suggest that pre-corrosion decreases the plasticity and fatigue life of the steel. Moreover, a low strain amplitude induces stronger degeneration of fatigue life than a high strain amplitude. Numerous fatigue cracks initiated from corrosion pits are observed. Corrosion pits provide favorable conditions for crack initiation, resulting in lower fatigue life. Moreover, the hydrogen embrittlement is identified as a contributing factor in the degeneration of fatigue life. A fatigue life prediction model is developed by considering the plastic loss induced by the pre-corrosion, and the prediction error between the results and experimental value is in the two-factor band. This work contributes to a deeper understanding of the fatigue behavior of rail steels and provides a simple way of engineering applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109118"},"PeriodicalIF":4.4,"publicationDate":"2024-11-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142747654","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":"Influence of milling stability on machined surface integrity and fatigue performance of Ti-6Al-4V titanium alloy","authors":"Mengyu Li ,&nbsp;Wei Zhao ,&nbsp;Liang Li ,&nbsp;Ning He ,&nbsp;Gabor Stepan","doi":"10.1016/j.engfailanal.2024.109103","DOIUrl":"10.1016/j.engfailanal.2024.109103","url":null,"abstract":"<div><div>Chatter is a deciding factor in milling operations regarding surface integrity and production efficiency. The purpose of this experimental research is to systematically investigate the influence of milling stability on machined surface integrity and fatigue performance of Ti-6Al-4V alloy samples. The surface integrity parameters like roughness, plastic deformation, microhardness, and residual stress were used to evaluate the machined surface quality. The fatigue tests were performed at five tensile stress levels with samples machined under stable, critical stable and unstable (chatter) cutting conditions. The experimental findings show that in comparison with samples produced by stable milling, the machined surface integrity parameters get worse with the increase of chatter amplitude and chatter marks, while fatigue test results show that the average fatigue life of these samples also decreases by about 20 %. The fatigue fracture morphology underscored that multiple fatigue cracks are initiated from the chatter marks on the machined surface. The experimental results provide a quantitative relation between the occurrence of chatter in milling operations and the life expectancy of the corresponding machined parts.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109103"},"PeriodicalIF":4.4,"publicationDate":"2024-11-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142746954","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":"Dynamic analysis of cutting RC structure with shield disc-cutter: Insights from the coupled simulation and laboratory test verification","authors":"Yidong Guo ,&nbsp;Dalong Jin ,&nbsp;Dajun Yuan ,&nbsp;Zheng Mou","doi":"10.1016/j.engfailanal.2024.109112","DOIUrl":"10.1016/j.engfailanal.2024.109112","url":null,"abstract":"<div><div>During shield tunneling in densely populated urban areas, shield machines may unexpectedly encounter obstacles such as reinforced concrete (RC) structure. Cutting through RC structure with a shield machine presents significant challenges due to potential cutter damage and reduced cutting efficiency. In this study, dynamic analyses of cutting RC structure via disc-cutter were performed based on the finite element method-discrete element method (FEM-DEM) coupled approach. In FEM-DEM coupled model, the mechanical behaviour of concrete is represented using DEM, while the influence of the rebar in the concrete is accounted for through FEM. And the precision and dependability of the simulation results were validated through the laboratory experiments. Overall, the numerical outcomes agreed well with the experimental data. Furthermore, a parametric study was conducted, and the effects of the shield working parameters and the geometric configurations of disc-cutter on the cutting performance of the disc-cutter were investigated, respectively. Through the parametric analysis, it is recommended that the shield machine adopts a tunneling pattern with low penetration and medium rotational speed in actual project when cutting the RC structure. The findings of this study may serve as valuable references for cutting RC obstacles with disc-cutters in future applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109112"},"PeriodicalIF":4.4,"publicationDate":"2024-11-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705892","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":"Performance research and effect evaluation of a high-grade damping fastener in subway line","authors":"Xiaogang Gao ,&nbsp;Haidong Yan ,&nbsp;Qingsong Feng ,&nbsp;Yufei Ma ,&nbsp;Maojin Du","doi":"10.1016/j.engfailanal.2024.109098","DOIUrl":"10.1016/j.engfailanal.2024.109098","url":null,"abstract":"<div><div>In recent years, some subway lines have been upgraded with vibration and noise reduction technology. As the only component connecting rail and sleeper, the fastener system has been the primary solution to vibration and noise reduction in subways. However, due to the mismatch between the structure design and material selection of the fastener system, the performance decay and aging failure of the fastener elastic pad occurred in less than one year of service in the line. In this paper, we choose a high-grade damping fastener with low vertical and high lateral stiffness as the research object, and explore the design method of fastener system to control the failure of stiffness aging and rail wear. Following that, theoretical analysis and experimental research are conducted on structural components of the higher damping fastener. The main conclusions are as follows: First, the stiffness of the damping fastener is adjustable in real time. By adjusting the nut installation height, optimizing the thickness of the elastic pad under the plate, and alerting the lateral block contact angle can change the vertical stiffness of fastener system by 19.4 %, 27.1 %, and 28.6 %, respectively. Second, before the line replacement, the rail roughness under the Egg type damper (Egg damper) is increasing exponentially. After replacing with the ZK type high-grade damping fastener (ZK fastener), the average roughness of high and low rails decreases at a rate of −0.3 dB/month. Third, hammering test results indicate that the vertical support stiffness of the ZK fastener is significantly lower than that of the Egg damper, while the lateral stiffness is 2.55 times greater than that of the Egg damper. Fourth, compared to the Egg damper before replacement, the maximum vertical vibration at the tunnel wall with the ZK fastener is reduced by 6.9 dB, and the dynamic twisting at the rail head is only half of the original. Application of the new damping fastener system in subway line replacement over the past two years not only reflects a clever stiffness design principle but also demonstrates good track stability, making it a preferred high-grade damping modification measure for controlling subway vibration and noise.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109098"},"PeriodicalIF":4.4,"publicationDate":"2024-11-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705822","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":"Modeling and analysis of internal excitation and vibration characteristics of gears with early-stage crack and 3D tooth surface error","authors":"Lantao Yang ,&nbsp;Kun Yue ,&nbsp;Liming Wang ,&nbsp;Fengshou Gu ,&nbsp;Andrew Ball","doi":"10.1016/j.engfailanal.2024.109116","DOIUrl":"10.1016/j.engfailanal.2024.109116","url":null,"abstract":"<div><div>Affected by the tooth surface errors, the vibration characteristics of early crack failures are usually various under different tooth surface precision level. Therefore, to reveal the influence of three-dimensional (3D) tooth surface error (TSE) on the internal excitation and vibration characteristics of gears with early-stage crack (ESC), a coupling internal excitation model of gears with ESC and 3D errors is proposed based on a double-layer iterative method. In this model, the influence of meshing phase between tooth pair and along tooth width direction (TWD) on the time-varying mesh stiffness (TVMS) are simultaneously considered, which overcomes the limitations of traditional models that are only suitable for characterizing the coupled excitation of the two-dimensional tooth profile errors and TVMS. Based on verifying the proposed model, the effects of TSE type, parameters, and load on the TVMS, loaded static transmission error (LSTE), load distributions, and torsional deformation of the cracked gear teeth are investigated, and the vibration characteristics of ESC failures under the effects of 3D TSE are also explored. The research results show that the distribution parameters of 3D TSE have a significant effect on the internal excitation and vibration characteristics of gears with ESC, and thus measuring and evaluating the distribution parameters of TSE can help improve the accuracy of gear fault identification and diagnosis methods.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"168 ","pages":"Article 109116"},"PeriodicalIF":4.4,"publicationDate":"2024-11-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142720566","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}