Engineering Failure Analysis最新文献

{"title":"Analysis of the impact of damage and strengthening of a steel spirit tank over its long lifetime","authors":"Sandra Mlonek,&nbsp;Monika Mackiewicz,&nbsp;Tadeusz Chyży","doi":"10.1016/j.engfailanal.2025.109546","DOIUrl":"10.1016/j.engfailanal.2025.109546","url":null,"abstract":"<div><div>Steel tanks for liquids are objects of great importance from the point of view of industrial development. They are often used for a considerable period of time and then the significant problem of assessing their technical condition arises. Previous repairs and strengthening are also important and should always be taken into account. As the tank wears out, the risk of an unexpected failure increases. The problem is whether only monitoring of the structure and the lack of significant deformation increase can be treat as a sufficient confirmation of further safe operation of the tank?</div><div>The aim of the presented research was to analyze the usefulness of the conducted assessment of the technical condition of the facility in terms of its further safe use. The article presents the results of the thorough analysis of the steel tank technical condition, which constitute the basis for further recommendations and guidelines for safe use. The analysis used available technical documentation including all previous inspections. Deformation measurements were carried out and the extent of damage to the tank was determined. The necessary conditions for its further possible operation were determined. Computer simulations of the tank were carried out, which showed that the proposed solutions would allow for further safe operation of the tank. The article includes the results of the FEM (Finite Element Method) computational analysis.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109546"},"PeriodicalIF":4.4,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143705333","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":"Vibration induced fatigue of mining and material handling mega machines","authors":"Przemysław Moczko,&nbsp;Maciej Olejnik,&nbsp;Damian Pietrusiak,&nbsp;Jędrzej Więckowski","doi":"10.1016/j.engfailanal.2025.109529","DOIUrl":"10.1016/j.engfailanal.2025.109529","url":null,"abstract":"<div><div>The article presents the current progress of research and development in of mining and material handling machines and focuses on estimation of the actual loads acting on the discussed objects, especially in the area of their undercarriage. In many cases, the standards currently used miss the case of verification fatigue scenario, or the values adopted are much lower than those observed during operation. The following paper briefly describes the possible consequences of failure in the machines described in article, the current approach of standards to fatigue, and the current progress of research and development in the context of fatigue calculations with respect to the alternating loads acting on the undercarriage. The described research will allow in the future to update the existing calculation standards or propose additional activities during the design of mining and material handling mega machines. This will allow for better optimization of the structure in terms of its resistance to fatigue damage.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109529"},"PeriodicalIF":4.4,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697180","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":"A novel analytical approach for 3D stability of unsaturated soil slopes with cracks under rainfall infiltration","authors":"Lei Zhang ,&nbsp;Xin Jiang ,&nbsp;Rong Sun ,&nbsp;Canyang Cui ,&nbsp;Hanyan Gu ,&nbsp;Yanjun Qiu","doi":"10.1016/j.engfailanal.2025.109545","DOIUrl":"10.1016/j.engfailanal.2025.109545","url":null,"abstract":"<div><div>Rainwater infiltration in unsaturated soil slopes with crest cracks can trigger two distinct three-dimensional (3D) failure modes: shallow translational failure along the slope face and deep-seated rotational failure at the crack tip. This study employs the upper-bound limit analysis method to present an analytical framework for the 3D stability analysis of unsaturated soil slopes with cracks under rainfall infiltration. Two kinematically admissible failure mechanisms are constructed: a novel composite mechanism combining a 3D horn-shaped block with an oblique cylinder to characterize translational failure, accounting for boundary effects at slope crest, toe, and lateral constraints; and a rotational failure mechanism based on the horn-shaped block. The wetting front model is adopted to capture the transient process of rainwater infiltration. The proposed method enables a unified evaluation of both shallow and deep-seated stability for slopes with arbitrary crack depths at the crest, and its effectiveness is validated by existing literature. Parametric studies are conducted to investigate the effect of slope geometry (width-to-height ratio) on stability and the controlling factors of the translational and rotational failures.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109545"},"PeriodicalIF":4.4,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143681992","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":"Clamping anti-derailment devices for high-speed trains","authors":"Fengqi Guo ,&nbsp;Yang Bai ,&nbsp;Liqiang Jiang ,&nbsp;Jiawei Qin ,&nbsp;Lizhong Jiang","doi":"10.1016/j.engfailanal.2025.109540","DOIUrl":"10.1016/j.engfailanal.2025.109540","url":null,"abstract":"<div><div>Ensuring the stability of high-speed trains under earthquake or crosswind hazards is essential for maintaining operation safety. Traditional anti-derailment methods, like guardrails and barrier walls, require extensive construction, leading to high costs and only take effect after the derailment. This study proposes a novel solution involving Clamping Anti-Derailment Device (CADD) mounted on train bogies to catch the track in hazardous conditions. Seven full scale CADD prototypes underwent monotonic pull-out loading tests, and a numerical model was developed to analyse their failure mechanisms. After model validation, parametric analyses were performed, and a theoretical model was established to simplify the load–displacement relationship of the devices. Additionally, a train-track dynamic model was constructed to assess the CADD performance under wind loads. The results showed that: (1) A CADD can provide 131.10 kN, and a pair of devices installed on each bogie is sufficient to resist the self-gravity of a single car. (2) The primary failure mode was the outward expansion of cantilever hook plate’s bottom end, causing no damage to the rail or bogie; (3) Under a 25 m/s crosswind at 350 km/h, the derailment coefficient decreased by 16.25 %. and under a 20 m/s crosswind at same speed, the wheel load reduction rate decreased by 8.16 %. The results demonstrate the potential of the CADD to enhance the safety and stability of high-speed trains under extreme conditions. Furthermore, a theoretical load–displacement model for the CADD was derived, providing a basis for future updates to the wheel-rail contact relationship in train-track-bridge coupled systems incorporating novel CADD.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109540"},"PeriodicalIF":4.4,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687751","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 segmental joint with DDCI connector and bolt under ultimate bending load based on DIC and AE","authors":"Yili Zhou ,&nbsp;Kun Feng ,&nbsp;Jialin Li ,&nbsp;Jiaqi Li ,&nbsp;Wenqi Guo ,&nbsp;Ruoyang Tang ,&nbsp;Mingqing Xiao ,&nbsp;Chuan He","doi":"10.1016/j.engfailanal.2025.109541","DOIUrl":"10.1016/j.engfailanal.2025.109541","url":null,"abstract":"<div><div>As the weakest parts of the shield tunnel linings, segmental joints require a thorough analysis of their damage evolution and failure mechanisms, which offer crucial insights for tunnel carrying capacity. For a new type of segmental joint consisting of a DDCI connector (consists of two D components, a C component and an I component) and three inclined bolts used in the Haitai Yangtze River Tunnel, a sequence of full-scale loading experiments was executed to investigate the failure characteristics of the segmental joints under sagging bending moment (SBM) and hogging bending moment (HBM). Digital image correlation (DIC) and acoustic emission (AE) were utilized in this study to investigate the damage process, failure mechanism, and mechanical properties of the segmental joint. The results indicate that the deformation and damage processes of the joint under SBM and HBM can be distinctly categorized into four stages. Upon entering the fourth deformation stage, a rapid increase in damage leads to a sharp decline in AE <em>b</em>-value. The joint primarily experiences compression-shear failure under SBM due to shear cracks, whereas tension cracks show a substantial rise under HBM. Under SBM, the failure characteristics of the joint involve concrete failure in the compressed region and significant bending of DDCI connector. In contrast, under HBM, the failure characteristics include concrete failure in the compressed region, damage to the concrete near the DDCI connector and fracture of the anchor rebars of the DDCI connector.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109541"},"PeriodicalIF":4.4,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687828","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":"Enhancement of bending fracture resistance of thin-walled stainless steel bellows with minor deformation through a new gradient strengthening strategy","authors":"Meng-ye Wang ,&nbsp;Meng Yan ,&nbsp;Ze-long Liu ,&nbsp;Yong Liu ,&nbsp;Hua-gui Huang","doi":"10.1016/j.engfailanal.2025.109538","DOIUrl":"10.1016/j.engfailanal.2025.109538","url":null,"abstract":"<div><div>To enhance the bending resistance of bellows and improve the combination effect of strength and toughness in the fracture-prone region (wave trough), gradient strengthening of the bellows was achieved through induction heat treatment. Firstly, the effects of various annealing parameters on the microstructure and mechanical properties of austenitic stainless steel subjected to minor deformation were systematically investigated using tensile testing, Gleeble thermal simulation experiments and material characterization techniques, which led to the identification of the optimal process parameters. Subsequently, based on the experimental results from the Gleeble tests, the temperature evolution in different regions of the bellows was regulated through induction heat treatment. The results indicated that the grain growth increased exponentially with heating temperature, and rapid grain coarsening occurred above 1100 °C, which significantly reduced the tensile strength of the material. A threshold for the heating rate was observed in controlling grain growth and enhancing the combination of strength and toughness. When the temperature rise rate exceeded 350 ℃/s, further improvements were negligible. The strategy of short-term heat preservation should be adopted, and the optimal comprehensive mechanical properties of materials were achieved at 5 s. Increasing the deformation amount (2 % ∼ 30 %) and cooling rate (80℃/s ∼ 170 ℃/s) helped to refine the grain size and improve the strength-ductility product of the matrix. The grain size was most sensitive to the holding time and heating temperature (from 20 μm to more than 50 μm), while the cooling rate had the most significant effect on the combination effect of strength and toughness of the matrix. Following induction heat treatment, the bellows exhibited a distinct gradient structure in grain size. Progressive refinement of grains was observed from the wave peak to the trough, accompanied by a concurrent enhancement of the combined effect of strength and toughness of the matrix. This gradient microstructure induced a mechanical property gradient, thereby effectively improving the bending resistance of the fracture zone (trough). Compared to bellows subjected to conventional furnace-based heat treatment, the gradient-strengthened bellows demonstrated a nearly 300 % increase in bending resistance. This study offers a valuable reference for optimizing the bending performance of bellows through induction heat treatment.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109538"},"PeriodicalIF":4.4,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687748","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel method for predicting mechanical properties of megacasting alloy based on the modified GTN model and machine learning","authors":"Qiangqiang Zhai ,&nbsp;Rensong Tang ,&nbsp;Zhao Liu ,&nbsp;Ping Zhu","doi":"10.1016/j.engfailanal.2025.109536","DOIUrl":"10.1016/j.engfailanal.2025.109536","url":null,"abstract":"<div><div>Megacasting, an advanced technology stemming from high-pressure die-casting (HPDC), offers the notable benefit of reducing costs while enhancing efficiency. Nevertheless, the rapid filling and cooling process inevitably leads to the problem of heterogeneous mechanical properties. Moreover, existing mechanical analysis methods struggle to accurately predict performances in defective castings, posing substantial challenges to the structural design megacastings. To meet this challenge, a high-precision hardening model that accounts for casting defects and saturation stress is proposed. And the shear-modified Gurson-Tvergaard-Needleman (GTN) damage model is adopted. The damage model parameters are identified by a novel framework that integrates machine learning method and optimization algorithm, which tackles the issues of high cost and low efficiency of traditional parameter identification methods. For the parameter calibration of hardening and damage models, different specimens are cut and machined from the megacasting. The results show that the proposed hardening model provides a higher fitting accuracy (<span><math><mrow><msup><mrow><mi>R</mi></mrow><mn>2</mn></msup><mo>&gt;</mo><mn>0.98</mn></mrow></math></span>) compared with the classical model. Additionally, the force–displacement curves of different specimens are compared, and the simulation is in good agreement with the experiment results. This verifies the reasonableness of the proposed framework for identifying the parameters of the damage model. Furthermore, based on the constructed machine learning model and the Sobol sensitivity analysis method, crucial parameters in the GTN damage model are identified. Local strain analysis is also performed on specimens with varied void levels. In conclusion, this study can serve as a valuable reference for the design of megacastings and contribute to the advancement of megacasting technology.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109536"},"PeriodicalIF":4.4,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687754","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":"Multi-physics microstructural modelling of a carbon steel pipe failure in sour gas service","authors":"M. Elkhodbia ,&nbsp;I. Gadala ,&nbsp;I. Barsoum ,&nbsp;A. AlFantazi ,&nbsp;M. Abdel Wahab","doi":"10.1016/j.engfailanal.2025.109469","DOIUrl":"10.1016/j.engfailanal.2025.109469","url":null,"abstract":"<div><div>This study presents a comprehensive failure analysis of an ASTM A106B steel pipe exposed to sour natural gas, focusing on degradation and cracking mechanisms. A range of experimental methodologies, including visual inspection, chemical spot tests, XRD analysis, SEM-EDS examination, metallographic analysis, and hardness testing, were employed to identify critical material deficiencies. The findings indicate that environmentally assisted cracking (EAC) initiated at the pipe’s outer diameter (OD) and propagated inward. The experiments also revealed a hardness gradient across the pipe’s thickness and a non-uniform distribution of microstructural inclusions. Additionally, a coupled chemo-mechano-damage finite element analysis (FEA) was conducted to simulate crack propagation driven by hydrogen embrittlement. The FEA used a phase-field approach to model interactions between hydrogen diffusion, mechanical stresses, and microstructural features such as non-uniform inclusion distribution and varying hardness across the pipe wall. The simulations successfully mimicked the crack growth path under sulphide stress cracking (SSC) conditions, demonstrating the influence of material inhomogeneity. The results confirmed that failure initiated at the OD and propagated inward due to hydrogen accumulation at inclusions. These inclusions caused higher gradients of hydrostatic stress, accelerating hydrogen accumulation and crack initiation in regions with a higher inclusion density. Regions of higher hardness were particularly susceptible to failure, as they exhibit lower fracture toughness, which is further degraded by hydrogen diffusion, accelerating the failure process. This study highlights the critical role of microstructural heterogeneities and hydrogen embrittlement in pipeline failure and suggests that the methods presented can be applied to pipelines in hydrogen blending or pure hydrogen transmission, offering key insights for improving material selection and design for pipelines in sour gas and hydrogen environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109469"},"PeriodicalIF":4.4,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687801","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":"Study on the low-cycle fatigue performance and failure behavior of IN718 coatings laser cladded on the surface of 27SiMn steel","authors":"Chao-ming Zhang ,&nbsp;Jia-jie Kang ,&nbsp;Lin-sen Shu ,&nbsp;Zhi-guo Xing ,&nbsp;Hai-dou Wang","doi":"10.1016/j.engfailanal.2025.109537","DOIUrl":"10.1016/j.engfailanal.2025.109537","url":null,"abstract":"<div><div>This study investigates the bonding characteristics and low-cycle fatigue failure behavior of laser cladding remanufactured coatings on 27SiMn steel. Optimized process parameters were employed to fabricate IN718 coatings via laser cladding on the surface of 27SiMn steel, and the coatings were heat-treated at 900 °C quenching +480 °C tempering. The results demonstrated that heat treatment enhanced the micro-hardness and bonding strength of the coatings by 10.3 % and 8.9 %, respectively. At 0.65 %–1.7 % strain amplitude, the cyclic softening behavior of the fatigue specimens was gradually enhanced as the strain amplitude increased. In larger strain amplitudes, the main crack of the fatigue specimen mostly originated from the position of the defect. The fatigue specimens with the main crack originating from the coating positions were more likely to fail. The study provides critical insights for advancing anti-fatigue remanufacturing engineering applications of 27SiMn steel.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109537"},"PeriodicalIF":4.4,"publicationDate":"2025-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687749","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A numerical approach to damage modelling for mechanical assessment of structural batteries","authors":"Weina Zhang,&nbsp;Dayou Ma,&nbsp;Andrea Manes","doi":"10.1016/j.engfailanal.2025.109535","DOIUrl":"10.1016/j.engfailanal.2025.109535","url":null,"abstract":"<div><div>Integrating lithium-ion polymer (LiPo) batteries into composite structures offers the potential to create multifunctional structural batteries that enhance both energy efficiency and structural reinforcement for lightweight design. While current research on structural batteries predominantly relies on experimental methods, there is a need for more systematic numerical studies to assess their structural integrity. This paper presents a holistic finite element (FE) computational model to evaluate the structural batteries’ mechanical performance and damage mechanisms under complex load cases. Various damage criteria and interactive models were employed to examine the behaviour of composite laminates and sandwich composites incorporating LiPo cells. Comparative analysis with experimental data from literature confirmed the FE model’s applicability and generality, though it showed slight variations in predictive modulus and post-yielding behaviour under bending. The numerical results indicate that the structural performance depends on specific design configurations and loading types. Sandwich composites exhibited minimal impacts resulting from battery integration, while the composite laminates had a notable decrease in structural strength. In addition, the presence of batteries strongly influenced the loading response and damage modes of the host structures. This numerical work provides valuable insights into the future design and health monitoring of structural energy storage systems.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109535"},"PeriodicalIF":4.4,"publicationDate":"2025-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687750","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}