Engineering Failure Analysis最新文献

{"title":"Progressive collapse disasters and control methods of tunnels in squeezed cataclastic rock mass: A case study","authors":"Siyue He ,&nbsp;Yibo Zhang ,&nbsp;Bo Wang ,&nbsp;Jinxing Lai ,&nbsp;Yapeng Fu ,&nbsp;Guoliang Li ,&nbsp;Zhanping Song","doi":"10.1016/j.engfailanal.2025.110177","DOIUrl":"10.1016/j.engfailanal.2025.110177","url":null,"abstract":"<div><div>Tunnels in cataclastic rock mass primarily faces challenges such as collapse, large deformations, which are further exacerbated by tectonic compression. This article employed the field monitoring data and numerical analysis to investigate the Ganqing Tunnel of the Xi’ning-Chengdu Railway as a case, and systematically studied progressive collapse disasters and proposed control methods in squeezed cataclastic rock mass. Results indicated that in-situ stress environment of cataclastic rock mass exhibited intense tectonic compression, characterized by the maximum horizontal principal stress far exceeding vertical stress, with ratio ranging from 2.01 to 2.34; rock mass integrity index ranged from 0.29 to 0.31, and strength ranged from 7.68 MPa to 24.03 MPa. Tunnel collapse was categorized into two types: instantaneous instability of surrounding rock at crown and instability of primary support at sidewalls, with the former being the most prevalent. The control methods including optimized cross diaphragm (CRD) method, dense advanced small duct grouting, radial grouting of crown and sidewalls, near-circular cross-section, and reinforced support system. Tunnel collapse frequency effectively decreased by 26.7 %, collapse scale reduced by 79.7 %, cumulative crown settlement decreased by 14.9 %, and cumulative horizontal convergence decreased by 15.7 %. After excavation and unloading of tunnel, four distinct stages included initial rock stress, unloading and rebound, opening and sliding of joint planes, and re-stabilization after collapse. Rock mass strength decreased significantly and particle bond failure within specific transverse and longitudinal zones due to opening and sliding of joint planes, and it was identified as primary factor contributing to tunnel collapse. The research findings can provide a valuable reference for the safe construction and structure design for similar tunnel projects in the future.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110177"},"PeriodicalIF":5.7,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216696","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":"Flood fragility of pipelines connected to above ground storage tanks","authors":"Md Manik Mia,&nbsp;Sabarethinam Kameshwar","doi":"10.1016/j.engfailanal.2025.110178","DOIUrl":"10.1016/j.engfailanal.2025.110178","url":null,"abstract":"<div><div>The objective of this study was to assess the flood fragility of pipelines connected to above-ground storage tanks and their contribution to resisting flotation and sliding of tanks. A large number of studies have assessed the risk of pipe failure for various threats such as corrosion, over pressure, and natural hazards like earthquakes, landslides, and sub-sea currents. But literature lacks studies that assess the flood performance of pipes connected to tanks, and the resistance offered by pipelines against tank flotation or sliding remains unknown. To address these issues, the response of pipelines subjected to flood loads was analyzed for two scenarios: (1) one end of the pipe was fixed while the other end was displaced to simulate tank flotation or sliding, and (2) the pipes were subjected to hydrostatic and hydrodynamic loads, with fixed boundary conditions at both ends to simulate a scenario without tank movement. Maximum von Mises stress was determined from the analysis and compared against failure thresholds for material yielding and rupture. Stepwise logistic regression was employed to develop fragility models for the four pipe layouts. The results indicated that layouts with expansion loops could withstand higher displacement without failure, under both flotation and sliding conditions. Additionally, the results revealed that for smaller tanks exposed to low to moderate flood depths, pipe resistance against sliding is significant and cannot be neglected.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110178"},"PeriodicalIF":5.7,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145265572","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":"Effects of ignition position and venting pipe on acetylene overpressure detonation: a CFD study","authors":"Xiaoliang Zhang ,&nbsp;Min Xiong ,&nbsp;Ronghan Guo ,&nbsp;Jun Zhang ,&nbsp;Jiawei Fang","doi":"10.1016/j.engfailanal.2025.110173","DOIUrl":"10.1016/j.engfailanal.2025.110173","url":null,"abstract":"<div><div>This paper investigates an overpressure detonation accident in a reactor containing acetylene and acetone. The study analyzes the damage to the reactor and surrounding structures, operating conditions of equipment, and material feeding operations to identify the causes of the accident. The displacement of the stirrer end gland and the top of the inner magnetic chamber following the explosion suggests an internal ignition source. Using the finite volume method, this paper investigates the formation of peak explosion pressure and the propagation characteristics of overpressure shock waves at different ignition positions within reactor R101. The impact of the size of the pressure relief plate and various venting pipe lengths (1.5 m, 3 m, 4.5 m, 8 m, 12 m, and 16 m) on the explosion relief process was also calculated. The results reveal that there is a peak explosion pressure variance of about 3.4 MPa, influenced by ignition position. The ignition position of the accident reaction is likely to occur in the area near the bottom of the stirring rod. When the diameter of the pressure relief plate is 0.12 m, the maximum pressure relief efficiency is 84.84 %. A venting pipe with a horizontal length of 8 m demonstrates a higher pressure relief efficiency during the explosion venting process. This research systematically examines the key factors influencing acetylene overpressure explosion accidents. These results might fill important gaps in accident analysis and reactor safety design, while strengthening the theoretical foundation for preventing accidents in high-pressure reactors.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110173"},"PeriodicalIF":5.7,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266200","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 and fatigue crack growth behavior of heavy duty rolling stock cast traction seats","authors":"Fan Zhang ,&nbsp;Chao Wang ,&nbsp;Tao Zhu ,&nbsp;Hongrui Qi ,&nbsp;Bing Yang ,&nbsp;Shoune Xiao ,&nbsp;Guangwu Yang","doi":"10.1016/j.engfailanal.2025.110179","DOIUrl":"10.1016/j.engfailanal.2025.110179","url":null,"abstract":"<div><div>This paper addresses the fatigue failure issues that occurred during the service of the welded traction seat. Combining finite element simulation and fracture analysis, it reveals that the primary failure mechanism is the combined effect of stress concentration and welding defects. Based on fracture mechanics methods, crack growth simulations were performed on the traction seat with different initial cracks, and a defect model was innovatively constructed that simultaneously considered the characteristics of the cast base metal and welding material. Comparison and verification of high-cycle fatigue test results and simulation results showed that the crack growth life prediction error was within 20%, confirming the validity of the model. In addition, the static distribution characteristics and dynamic variation laws of the stress intensity factor in the high-incidence area of cracks in the traction seat base were analyzed in detail, and the relationship between the initial crack depth, shape ratio, and structural bearing capacity was explored. The results show that under a traction braking load of 285/200 kN, initial cracks of any size at the bottom of the welded traction seat will grow. Based on these results, a safety threshold for the load-bearing capacity of welded traction seats was proposed, providing a theoretical basis and practical guidance for accident prevention in service traction seats.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110179"},"PeriodicalIF":5.7,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145265524","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 for the strength of hard rock after hydraulic fracturing: An experimental investigation on improving cuttability of hard rock","authors":"Wentao Hou ,&nbsp;Dan Ma ,&nbsp;Qiang Li ,&nbsp;Zhisong Ma ,&nbsp;Changle Xu ,&nbsp;Quanhui Liu ,&nbsp;Jinghong Yan","doi":"10.1016/j.engfailanal.2025.110175","DOIUrl":"10.1016/j.engfailanal.2025.110175","url":null,"abstract":"<div><div>In order to address the challenges of low rock-breaking efficiency and high energy consumption in hard rock roadway excavation, this study proposes the hydraulic fracturing-assisted mechanical rock breaking technology. Firstly, hydraulic fracturing tests were conducted. Secondly, the effects of hole-edge distance, hole pitch, lithology, cutting rate, and cutting head rotational speed on the rock cutting performance after hydraulic fracturing were analyzed based on mechanical cutting experiments. The results indicate that the fracture morphology primarily consists of spalling and short-axis fractures following single-hole hydraulic fracturing, while double-hole hydraulic fracturing induces both short-axis and long-axis fractures. In single-hole fracturing, the optimal hydraulic drilling position is located at the center of the sample. For double-hole fracturing, the optimal hole-edge distance is 10 cm, achieving minimal specific cutting energy consumption and peak cutting force. After hydraulic fracturing, granite and basalt still exhibit strong cutting resistance, and sandstone and limestone demonstrate a significant decline in the cutting index. Under moderate cutting rates and cutting head rotation speeds, energy utilization efficiency is maximized, significantly reducing cutting energy and specific energy consumption. Finally, this study validates the accuracy of the traditional non-hydraulic fracturing specific energy consumption prediction model against experimental results and proposes incorporating a hydraulic fracturing cutting factor to refine the prediction model, thereby enhancing its accuracy.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110175"},"PeriodicalIF":5.7,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216625","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":"Buckling failure prediction of storage tanks in fire scenarios: a machine learning approach","authors":"Shenbin Xiao ,&nbsp;Lijun Wei ,&nbsp;Tao Zeng ,&nbsp;Haishun Wang ,&nbsp;Guoliang Yang ,&nbsp;Chao Chen","doi":"10.1016/j.engfailanal.2025.110157","DOIUrl":"10.1016/j.engfailanal.2025.110157","url":null,"abstract":"<div><div>Storage tanks are common pressure vessels in chemical industrial parks. Their risks in fire scenarios are characterized by dynamics and coupling. Therefore, the failure analysis and prediction of storage tanks are of great significance for the safety of chemical industrial parks. Previous studies focus on the static characteristic analysis of storage tanks, while research on dynamic thermo-mechanical coupling response mechanisms and failure prediction remains limited. Additionally, conventional numerical methods typically incur substantial computational costs in multi-parameter coupling analysis. The methods also lack universality across different application scenarios and exhibit insufficient timeliness in delivering analysis results. This study establishes a dual-driven “numerical simulation-machine learning” framework and employs finite element analysis to develop a solid double-layer flame model combined with the artificial damping method (ADM) to simulate dynamic thermomechanical responses and buckling failure processes. This study incorporates three machine learning models—Backpropagation Neural Network, Convolutional Neural Network, and Random Forest—to develop a predictive methodology for tank buckling failure under multi-parameter coupling conditions. The methodology is based on numerical analysis results of the height-to-diameter ratio, liquid height, and pool flame height. The models are trained using these geometric and thermal parameters as inputs, with the buckling failure time of the storage tank as the output. This method systematically compares the mean relative error to identify the optimal predictive model, effectively capturing the complex nonlinear characteristics of storage tank failure mechanisms. The results reveal the liquid level and height-to-diameter ratio delay failure through specific heat capacity and structural effects, while pool flame height prolongs failure via thermal radiation. The Backpropagation neural network demonstrates optimal performance. This prediction model enables real-time prediction of tank failures in fire scenarios and provides an innovative solution for the intelligent upgrade of safety protection in tank farms.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110157"},"PeriodicalIF":5.7,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216698","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":"Coupled effects of pre-corrosion and high temperature on the degradation behaviour and wear failure of gun steel","authors":"Ao Wei ,&nbsp;Xiaohui Zhao ,&nbsp;Ruirui Dai ,&nbsp;Siyu Peng ,&nbsp;Lingbing Shi ,&nbsp;Teng Ma ,&nbsp;Xianhua Tian ,&nbsp;Junfeng Yuan","doi":"10.1016/j.engfailanal.2025.110170","DOIUrl":"10.1016/j.engfailanal.2025.110170","url":null,"abstract":"<div><div>The failure of gun barrels under marine corrosion and high temperatures limits the service life of naval weapon systems. This study investigates the degradation and wear mechanisms of 30CrNi2MoVA gun steel during the initial extrusion phase under simulated marine conditions. Pre-corrosion was induced using 3.5 wt.% NaCl immersion, followed by sliding wear tests at 25 °C, 400 °C, 600 °C, and 800 °C. Results show that high temperatures reduce strength and hardness, while pre-corrosion exacerbates surface damage. At 600 °C and 800 °C, wear rates surged—6–8 times higher than at room temperature—indicating severe failure. Wear mechanisms shifted from abrasive and adhesive wear to a combination of adhesive, oxidative, and fatigue wear at elevated temperatures, linked to corrosion-induced microstructural defects and thermal softening. These findings enhance the understanding of early-stage barrel failure in marine environments and support the development of better materials and protective strategies.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110170"},"PeriodicalIF":5.7,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216695","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":"Characterization of failure behavior in secondary brass","authors":"Xiao Wang ,&nbsp;Wei Liu ,&nbsp;Shengli Chai ,&nbsp;Yinghui Wei","doi":"10.1016/j.engfailanal.2025.110172","DOIUrl":"10.1016/j.engfailanal.2025.110172","url":null,"abstract":"<div><div>Due to its excellent mechanical and physical properties, brass finds extensive industrial application. While the recycling of scrap brass is vital for achieving sustainable resource utilization, the failure of secondary brass products represents a critical challenge. In this paper, fracture analysis was conducted on defective samples including fractured intermediates and final products. Through examination of fracture morphology and elemental distribution, the failure mechanisms were elucidated. The results revealed that impurities—including Pb, Fe, Al, and O—segregated at grain boundaries, forming a rigid and brittle intergranular layer. This microstructural feature compromised grain boundary cohesion, increasing propensity for crack initiation and propagation. Structural defects arose primarily from the segregation of Zn content during the smelting of secondary brass, causing the formation of ZnO and γ-phase precipitates. As hard and brittle phases, these phases promoted a mixed fracture mode, characterized by dimpled rupture and intergranular cracking. Additionally, machined components frequently exhibited surface irregularities and pronounced plastic deformation during manufacturing. To mitigate these issues, comprehensive process control strategies were proposed. This paper established a critical linkage between the failure mechanisms of secondary brass products and their intrinsic determinants—material composition, microstructure, and processing conditions—offering valuable insights for improving product quality and operational reliability.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110172"},"PeriodicalIF":5.7,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216694","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":"Impact of RC mid-size span slabs with drop panels","authors":"David.Z. Yankelevsky ,&nbsp;Yuri.S. Karinski ,&nbsp;Dina Tsemakh ,&nbsp;Vladimir R. Feldgun","doi":"10.1016/j.engfailanal.2025.110151","DOIUrl":"10.1016/j.engfailanal.2025.110151","url":null,"abstract":"<div><div>This paper deals with reinforced concrete buildings constructed from flat slabs that are supported by columns. The slab-column connections are responsible for transferring the slab loads to the columns; hence failure of these connections is critical to the building stability. This paper focuses on mid-size slabs (4-meter to 8-meter span) and investigates the impact between a falling slab with a slab at a typical floor height below. The slab may fall due to its connections’ failure for any cause (e.g., excessive loading). The impacted slab may survive the impact or undergo connections impact failure. It was found that such high intensity impact between flat slabs without drop panels (DPs) causes failure of the impacted slab connections, thus initiating a progressive collapse scenario, while added DPs at the slab-column connections may improve the connection resistance. This paper investigates the response of slabs with and without DPs to the same impact. The investigation also examines the effects of several parameters on the impacted slab response, such as added bent up shear reinforcement, and examines the supporting columns cross-section dimensions effects on the response and the damage. Although use of bent-up shear rebars is not mandatory for thick slabs under static loading, the effect of bent-up rebars was examined for 6-meter span slabs. It was found that in such slabs without shear reinforcement, the slab-column connections fail under slabs impact. When minimum cross-section dimensions of the supporting columns were used, the structural system could not survive the impact and failure was observed with the following characteristics: for slabs with small DP width − dynamic punching shear failure occurred, where the slab shear failure occurred beyond the DP domain; for mid-size DP width − dynamic punching failure occurred with failure crossing the DP domain; for larger DP width, concrete column failure accompanied by reinforcement buckling occurred, dominating the entire failure. Column failure did not develop in shorter span slabs. When column failure appears, it overshadows the slabs connections failure due to its major effect on the global failure of the structural system. However, column failure can be avoided by extending the column cross-section dimensions. Repeated analyses with sufficiently large column cross-sections show that dynamic punching shear failure of the slab-column connections develop in cases of small width or large width DPs, however intermediate size DPs survive the impact without connections failure, ending with small to moderate permanent displacements of the impacted slab. This is a pronounced improvement compared to the failure of similar slabs without DPs. An optimal DP width has been identified that yields a minimum permanent deflection of the slab.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110151"},"PeriodicalIF":5.7,"publicationDate":"2025-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216697","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 and degradation analysis of orthopedic implants removed from human bodies","authors":"Beata Swieczko-Zurek ,&nbsp;Marcin Nowak ,&nbsp;Jean Marc Olive ,&nbsp;Marcin Strakowski ,&nbsp;Paulina Strakowska ,&nbsp;Przemyslaw Paradowski ,&nbsp;Jakub Karczewski ,&nbsp;Marek Ptak ,&nbsp;Alina Sionkowska","doi":"10.1016/j.engfailanal.2025.110168","DOIUrl":"10.1016/j.engfailanal.2025.110168","url":null,"abstract":"<div><div>Materials placed in the body should be indifferent to the surrounding environment, and at the same time fulfill their functions. By assumption, they should be biocompatible, biofunctional and serve according to their intended use. After the implant is introduced in living tissues, the immune system responds. In order for the implant to be accepted by the body, many factors must be involved. The research contained in the article describes the phenomena occurring on an implant in a living organism. Those tests show the surface degradation of the material, by using a scanning electron microscope (FEI Quanta FEG 250) and optical coherence tomography (OCT). The tests show the surface and material damage of the tested samples.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"182 ","pages":"Article 110168"},"PeriodicalIF":5.7,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216560","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}