Engineering Failure Analysis最新文献

{"title":"Quantitative analysis and optimization of residual stress fields near fastener holes under combined factors","authors":"Zhiqiang Gan ,&nbsp;Lei Gan ,&nbsp;Yonghui Su ,&nbsp;Dongheng Ru ,&nbsp;Hao Wu ,&nbsp;Reza Talemi","doi":"10.1016/j.engfailanal.2025.109404","DOIUrl":"10.1016/j.engfailanal.2025.109404","url":null,"abstract":"<div><div>Residual stress surrounding the expanded hole, generated by cold expansion process, plays a pivotal role in enhancing fatigue life but is susceptible to multiple factors. Accurate comprehension of the residual stress field is the essential prerequisite for addressing the fatigue failure problem of fastener holes. In this study, 2D-Digital Image Correlation (DIC) and X-ray Diffraction (XRD) were employed to measure the residual strain and stress of hole plate subjected to split sleeve cold expansion (SSCE) under varying conditions. A 3D finite element (FE) model for tapered mandrel expansion was developed and validated against experimental results. A novel index, termed the effective residual stress, was proposed to quantitatively evaluate the residual stress field. Furthermore, the distribution characteristics of residual stress field were predicted and optimized using machine learning (ML) algorithm, considering the combined effect of the degree of cold expansion (DE), thickness of the plate, and edge distance ratio (EDR). Results indicate a nonlinear relationship between the effective residual stress and both thickness and EDR, and the influence of EDR is greater than thickness. For plates with varying thickness and EDR, the optimal DE varies from 3.5 % to 5.0 %. Specifically, when the EDR is below 3.5 and the thickness is below 10 mm, the optimal DE falls within the range of 3.5 % to 4 %.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109404"},"PeriodicalIF":4.4,"publicationDate":"2025-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395464","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":"Optimal intensity measures for probabilistic seismic demand modeling of single-domed historical masonry buildings","authors":"Fuat Akturk ,&nbsp;Ali Yesilyurt ,&nbsp;Ferit Cakir","doi":"10.1016/j.engfailanal.2025.109378","DOIUrl":"10.1016/j.engfailanal.2025.109378","url":null,"abstract":"<div><div>This study aims to identify the optimal intensity measures for use in probabilistic seismic demand models for single-domed historical masonry buildings. Developing a probabilistic seismic demand model that describes the relationship between strong ground motion intensity measures and engineering demand parameters is critical in the performance-based earthquake engineering framework. To this end, a methodology is presented for selecting optimal intensity measures based on correlation, efficiency, practicality, proficiency, and sufficiency criteria. The 38 intensity measures commonly used in seismic vulnerability and risk assessments are categorized as follows: (i) earthquake-based, (ii) structure-based, (iii) event-based, and (iv) compound-based. Shear Stress, Normal Stress, Maximum Normal Strain, and Maximum Drift Ratio were used as engineering demand parameters to measure the structural response. In this study, the Elbistan Ulu Mosque, which was damaged after February 6, 2023, Mw7.8 and Mw7.5 Kahramanmaras earthquakes, was selected as a case study to determine the appropriate intensity parameters. For this purpose, response spectrum analyses were conducted on a 3D finite element model of the selected historical masonry structure to assess its response under seismic events. Various probabilistic seismic demand models were developed, and numerous regression analyses were performed between the engineering demand parameter and the intensity measures. After conducting thorough analysis and evaluation, spectral acceleration, spectral displacement, and modified cordova intensity were determined to be the most suitable intensity measure parameters. In addition to these optimal intensity measures, fragility curves were subsequently developed based on other relevant intensity measures, including peak ground acceleration, effective design acceleration, and A95.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109378"},"PeriodicalIF":4.4,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143388166","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 typical cases of corrosion failure of tubing in heavy oil fire-flooding production wells","authors":"Dezhi Zeng ,&nbsp;Xue Han ,&nbsp;Chengxiu Yu ,&nbsp;Chunyan Zheng ,&nbsp;Rigu Su ,&nbsp;Jianghe Sun ,&nbsp;Yiyang Li ,&nbsp;Jie Chen","doi":"10.1016/j.engfailanal.2025.109391","DOIUrl":"10.1016/j.engfailanal.2025.109391","url":null,"abstract":"<div><div>A corrosion failure of tubing often occurs during the production process of production wells in heavy oil fire-flooding blocks and thus affects service safety. In the study, the service information of tubings in fire-flooding blocks was analyzed and the physical and chemical properties of defunct tubings were determined. In addition, the causes for the failures of series tubings with wall thickness thinning and corrosion perforation were revealed by SEM, EDS, and XPS. The common corrosion types of tubings and the inducing factors of different failure forms were clarified and corresponding anti-corrosion suggestions were given. The material of defunct tubings was not the failure cause. When high-temperature gas channeling and unburned O₂ occurred, corrosion was intensified by a high content of Cl⁻, thus resulting in the corrosion failure of series tubings with serious wall thickness thinning. When a high content of Ca^2 + existed in formation water, a CaCO₃ scale layer was formed to adhere to the outer wall of the tubing and aggravate local corrosion under the action of a high content of Cl⁻. This above process was the cause for corrosion perforation. CO₂/H₂S corrosion generally occurred in the tubings of fire-flooding production wells. The inducing factors of tubing failures included high-temperature gas channeling, unburned O₂, a high content of Ca^2 +, and a high content of Cl⁻. It is recommended to use imidazoline corrosion inhibitor XCN-ZO2 and annular outer wall aluminum-based sacrificial anode anti-corrosion short sections for corrosion protection.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"172 ","pages":"Article 109391"},"PeriodicalIF":4.4,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427720","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 metallic bolted joints under multiaxial fatigue loading","authors":"Maxime Nutte ,&nbsp;Vincent Bonnand ,&nbsp;Benjamin Delpuech ,&nbsp;Pascale Kanouté ,&nbsp;Serge Kruch","doi":"10.1016/j.engfailanal.2025.109347","DOIUrl":"10.1016/j.engfailanal.2025.109347","url":null,"abstract":"<div><div>This paper investigates the fatigue performance of metallic bolted assemblies under multiaxial loading, focusing on biaxiality ratios and applied forces. It integrates experimental tests and complex 3D finite element simulations to analyse mechanical fields and correlate crack initiation sites with stress fields. A geometry for metallic bolted assemblies is introduced, facilitating various proportional and non-proportional loadings. Specimens made from 2024-T351 aluminium alloy allow a theoretical 90°disorientation between by-pass and bearing forces. These specimens undergo biaxial fatigue tests on a specialized machine to study the effects of stress rotation on the macroscopic mechanical response. Fracture surface analysis identifies three distinct crack initiation sites based on biaxiality ratios: low ratios result in net-section failures driven by by-pass stress, high ratios lead to gross-section failures influenced by bearing stress, and an intermediate range shows mixed initiation sites. Fatigue performance is characterized by Wöhler curves, highlighting the detrimental effect of bearing load on fatigue life. A new <span><math><msub><mrow><mi>F</mi></mrow><mrow><mtext>By-Pass</mtext></mrow></msub></math></span>-<span><math><msub><mrow><mi>F</mi></mrow><mrow><mtext>Bearing</mtext></mrow></msub></math></span> diagram visualizes biaxiality’s influence on fatigue performance, revealing by-pass dominated, bearing dominated, and mixed regimes. The findings underscore the complex relationship between biaxial loading, crack initiation, and fatigue life, aiding the design of lightweight, high-performance aircraft structures.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"172 ","pages":"Article 109347"},"PeriodicalIF":4.4,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143437381","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":"Experimental study on the failure characteristics of the loess high slope under the coupled effects of soil Consolidation, Rainfall, and evaporation","authors":"Zhuangfu Zhao ,&nbsp;Yanpeng Zhu ,&nbsp;Shuaihua Ye","doi":"10.1016/j.engfailanal.2025.109383","DOIUrl":"10.1016/j.engfailanal.2025.109383","url":null,"abstract":"<div><div>The stability of loess high-fill slopes is a crucial issue in engineering, where the presence of fissures significantly impacts slope stability. This study investigates the seepage-mechanical response and fissure evolution characteristics of loess high-fill slopes under the coupled effects of consolidation, rainfall, and evaporation through model testing. The disaster chain evolution process of the slope under these coupled effects is revealed. The results show that the development of fissures in loess high-fill slopes does not follow a directional pattern and has a uniform influence on soil properties. Under rainfall, the slope exhibits preferential flow paths, which guide the deformation and failure modes. With the development of fissures, the fill material shows a “cumulative damage effect,” leading to progressive performance degradation and continuous decline in slope stability. This study enriches the theoretical framework for stability analysis of high-fill fissured slopes and provides guidance for disaster prevention and mitigation in loess regions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109383"},"PeriodicalIF":4.4,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143376688","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":"Synergistic degradation effects of environmental factors on dam concrete: Experimental insights and constitutive model","authors":"Xing Xia ,&nbsp;Jinjun Guo ,&nbsp;Hongyin Xu ,&nbsp;Peng Zhang","doi":"10.1016/j.engfailanal.2025.109399","DOIUrl":"10.1016/j.engfailanal.2025.109399","url":null,"abstract":"<div><div>The constitutive properties of dam concrete under environmental influences are critical for evaluating the reliability of hydraulic structures. To address this issue, referring to the concrete mix proportions of high-arch dams in Southwest China, several groups of wet-screened concrete were prepared to investigate the evolution of the mechanical and constitutive properties of dam concrete under the combined influence of multi-environmental factors. Based on meteorological data in Southwest China, a long-term deterioration test system was designed, which coupled temperature and humidity cycling (THC) and salt spray erosion (SSE). In the initial stage, the generation of swelling products led to a slight increase in both mechanical properties and dynamic elastic modulus. As the deterioration period progressed, the expansion of micro-cracks and the degradation of hydration products gradually occurred within the microstructure, leading to stages of both slow and accelerated performance decline. The peak stress and the initial elastic modulus in the constitutive curve showed similar evolutionary trends. The results indicated that the synergistic deterioration effects of THC-SSE were significant, especially adjacent to the surface. THC directly facilitated mass loss and micro-crack development, thereby accelerating SSE. A detailed assessment of the loading capacity of dam concrete was conducted through energy analysis. Furthermore, the proposed model accounts for the characteristics of internal damage distribution in concrete drawing on the homogenization theory. And a novel perspective is provided for investigating constitutive models of concrete with non-uniform internal damage fields. Herein, the experimental and modeling findings provide essential data and theoretical support for the design and evaluation of dam concrete exposed to long-term complex environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109399"},"PeriodicalIF":4.4,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143402880","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 the behavior of the mullite samples surface exposed to the cavitation using a statistical analysis approach","authors":"Ana Alil ,&nbsp;Sanja Martinović ,&nbsp;Dragana Živojinović ,&nbsp;Tatjana Volkov Husović","doi":"10.1016/j.engfailanal.2025.109402","DOIUrl":"10.1016/j.engfailanal.2025.109402","url":null,"abstract":"<div><div>Cavitation erosion which occurs under specific fluid flow conditions in industrial processes, demands suitable materials. This study investigates the cavitation resistance of mullite by observing surface changes during exposure. A novel method focuses on morphological descriptors of defects caused by cavitation. Using image analysis (IA), surface degradation was quantified by selecting specific defect parameters, with datasets analyzed through principal component analysis (PCA) to identify key damage descriptors. This approach simplified the estimation of lifespan for exposed parts. The PCA of datasets obtained from IA indicated that the most informative descriptors of surface damage vary remarkably throughout the cavitation and per different periods of the cavitation curve. Among eleven selected parameters, PCA identified critical parameters <em>Radius_max</em>, <em>Perimeter</em>, and <em>Size_length</em> consistent throughout testing for monitoring mullite’s cavitation resistance. By combining traditional, non-destructive methods and statistical analysis, this study offers a new framework for tracking surface damage progression. This enables a deeper understanding of cavitation-induced material erosion, improving predictions of material performance and optimizing industrial applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109402"},"PeriodicalIF":4.4,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143388165","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 the deposition strategy and endogenous defect pattern on the plastic deformability and the fracture mechanism of 316L stainless steel obtained using material extrusion","authors":"Sergio Lorenzi ,&nbsp;Gianluca D’Urso ,&nbsp;Lorenzo Nani ,&nbsp;Mariangela Quarto ,&nbsp;Stephanie Fest-Santini ,&nbsp;Tommaso Pastore","doi":"10.1016/j.engfailanal.2025.109395","DOIUrl":"10.1016/j.engfailanal.2025.109395","url":null,"abstract":"<div><div>In the metal additive manufacturing (MAM) scenario, metal-polymer-based systems such as material extrusion (MEX) and binder jetting (BJ) are gaining increasing interest as they are expected to provide production cost savings alongside increased productivity compared with well-established powder bed fusion (PBF) and direct energy deposition (DED) technologies. However, metal-polymer-based systems are multistep processes characterized by internal porosity which is strictly dependent on the adopted manufacturing technology in terms of size, shape and distribution. This study examined the impact of such endogenous defects on the tensile behavior of 316L stainless steel manufactured with two different deposition strategies, i.e. the conventional ± 45° and an experimental strategy borrowed from PBF processes, that consists of 67° rotation of each layer<em>,</em> namely <em>k</em>67°. The microstructure consisted mostly of equiaxed austenitic grains with segregation of δ-ferrite at the grain boundaries in all the studied conditions, as expected. The overall volumetric porosity was close to 2 % for both deposition strategies, but the morphology of macro-defects was significantly different. The distribution of defects assessed using micro computational tomography (micro-CT) showed a periodic, stacked, and continuous macro-defect pattern for ± 45° strategy, whereas a more distributed, fragmented and discontinuous pattern was observed for the <em>k</em>67° strategy. The tensile tests curves highlighted a broad and homogeneous plastic deformation without any noteworthy evidence of necking. The fracture morphologies were characterized by a preferential fracture propagation path driven by porosity pile-up for both infill strategies. This resulted in higher deformations at break for the <em>k</em>67° strategy specimens than for the conventional ± 45°. The δ-ferrite regions found at the austenitic grain boundaries functioned as preferential sites for crack initiation, while propagation was almost ductile in bulk.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109395"},"PeriodicalIF":4.4,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143372763","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":"Failure analysis and design improvement of a hot ironing die holder","authors":"Ali Yetgin,&nbsp;Aptullah Karakaş,&nbsp;Bülent Acar,&nbsp;Emre Özaslan","doi":"10.1016/j.engfailanal.2025.109397","DOIUrl":"10.1016/j.engfailanal.2025.109397","url":null,"abstract":"<div><div>Hot ironing is a hot metal forming process where a cup shaped workpiece was pushed through ring-shaped dies. The workpiece elongates as process goes while its wall thickness decreases. The rings are held by a holder piece which should be sized to have enough stiffness and load-bearing capacity. Also, the diametral stability and structural capacity of the rings are supported by die holder structure. Failure of a die holder was investigated on metallurgical and numerical basis. First, metallurgical tests were performed to evaluate hardness, chemical composition and microstructure. Then, detailed finite element models were created to observe general stress distribution in the part as well as identifying possible hot spots for failure initiation. During metallurgical examinations, the material was observed to contain carbides which induce brittle behavior. Additionally, the threaded holes used to assist in the disassembly of the rings cause significant stress concentration. After evaluation of both metallurgical and numerical studies, the failure that initiated from stress concentration around threaded hole was explained in detail. Furthermore, design was improved by removing threaded holes that cause stress concentration.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109397"},"PeriodicalIF":4.4,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143402529","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 compression-after-impact of CFF/PEEK thermoplastic composites subjected to double-position impact based on DIC and Micro-CT techniques","authors":"Jiqiang Hu ,&nbsp;Yingze Li ,&nbsp;Zhongyu Li ,&nbsp;Chunming Ji ,&nbsp;Jiecai Han ,&nbsp;Bing Wang","doi":"10.1016/j.engfailanal.2025.109396","DOIUrl":"10.1016/j.engfailanal.2025.109396","url":null,"abstract":"<div><div>Compared to single-position impacts (including both single and multiple impacts), multi-position impacts on fiber-reinforced polymer (FRP) composites are more common in engineering applications, yet this scenario is often overlooked in existing research. Moreover, evaluating the load-bearing performance of FRP composites after impact is of great significance. Therefore, this study focuses on the compressive behavior of CFF/PEEK thermoplastic composites subjected to double-position impacts. Utilizing digital image correlation (DIC) and micro-CT scanning techniques, the effects of impact energy and impact spacing on the mechanical response, damage evolution, and failure morphology of compression-after-impact (CAI) are extensively analyzed. The results indicate that the strength of CAI is mainly dominated by impact energy, which significantly decreases with increasing impact energy, but is weakly affected by the impact spacing. And the local buckling load and stiffness of CAI are sensitive to impact energy and impact spacing. The failure mode of CAI is primarily influenced by the level of impact energy; however, the deformation evolution process of CAI depends on both impact energy and impact spacing. The failure morphology of CAI is primarily associated with the impact energy level. For low impact energy level events, the transverse failure morphology is continuous penetrating delamination, and the longitudinal failure morphology is dominated by shear fracture; whereas for high-impact energy level events, the transverse failure morphology is multi-segmented delamination, and the longitudinal failure morphology involves a combination of shear and delamination failure modes. This study provides a technical idea for investigating the CAI behavior of FRP composites subjected to multi-position impacts.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109396"},"PeriodicalIF":4.4,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143376690","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}