Engineering Failure Analysis最新文献

{"title":"Dynamic split tensile behaviour of different rocks pre-treated with sulphuric acid: Effect of long exposure durations and pH of acid","authors":"Anand A ,&nbsp;Kumar S ,&nbsp;Tiwari G ,&nbsp;Venkitanarayanan Parameswaran","doi":"10.1016/j.engfailanal.2026.110615","DOIUrl":"10.1016/j.engfailanal.2026.110615","url":null,"abstract":"<div><div>Rocks are often subjected to acidic environments due to both natural (e.g., acid rain) and anthropogenic factors (e.g., nuclear waste repositories), in addition to dynamic loading conditions. To investigate their response under such conditions, an extensive experimental program comprising 160 tests was conducted to study the dynamic tensile behavior of acid-treated rocks. Five representative rock types were selected based on their distinct origins, outcrop locations, mineralogical characteristics, and frequent use in construction projects: Makrana marble, Kota limestone, and three granite varieties, i.e., Colonial White, Rajasthani Black, and Jhansi Red. Circular disc specimens were prepared and exposed to sulphuric acid solutions of varying pH (1–5) for durations ranging from 30 to 120 days, simulating long-term in-situ conditions, an aspect relatively less explored in rock mechanics. The acid-treated specimens were then tested under dynamic loading using the Brazilian Disc (BD) method in a Split Hopkinson Pressure Bar (SHPB) setup. Fracture propagation was continuously monitored through high-speed camera-assisted Digital Image Correlation (DIC). The underlying micro-mechanisms governing the macroscopic response were further examined using X-Ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and petrographic thin-section analysis. Results revealed a progressive reduction in dynamic tensile strength with decreasing pH and increasing exposure duration, with limestone showing the greatest strength loss due to its higher susceptibility to chemical disintegration. Acid exposure also significantly influenced fragmentation behavior, with Fragment Size Distributions (FSDs) shifting toward well-graded types and the Average Fragment Size (AFS) reducing, attributed to grain and grain-boundary degradation. These findings highlight the coupled chemical–mechanical degradation processes in rocks subjected to acid environments under dynamic loading.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110615"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075810","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure investigation of gears on a tyre manufacturing machine","authors":"MN James ,&nbsp;D Bernard ,&nbsp;C Louis ,&nbsp;L. Matthews ,&nbsp;DG Hattingh","doi":"10.1016/j.engfailanal.2026.110593","DOIUrl":"10.1016/j.engfailanal.2026.110593","url":null,"abstract":"<div><div>This failure investigation deals with an apparently straightforward case of gear failure that was undertaken to see whether it contained any cracking that pre-existed the final fracture of a tooth. Some interesting features were observed in this case, as there were several cracks in the gear besides the primary one that led to fracture, showing evidence of at least two different crack initiation mechanisms. These mechanisms were intergranular quench cracking, occasionally involving large inclusions where chevron markings were seen on the ductile fracture surface that pointed back to the local fracture origin, and the observation of very localised intergranular oxidation in the carburised case of the gear that occurred during heat treatment. Both mechanisms of crack initiation then led to fatigue cracking. The final conclusion was that the gears failed prematurely from fatigue cracking initiated by intergranular oxidation combined with an impact load.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110593"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146025777","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":"Collapse mechanism of deep-buried long water-rich basalt tunnels based on integrated geophysical prospecting: A case study in Yunnan, China","authors":"Pengfei Ma ,&nbsp;Yangyang Zhang ,&nbsp;Lichao Nie ,&nbsp;Zhiqiang Li ,&nbsp;Zhicheng Song ,&nbsp;Yuancheng Li","doi":"10.1016/j.engfailanal.2026.110581","DOIUrl":"10.1016/j.engfailanal.2026.110581","url":null,"abstract":"<div><div>Collapse is likely when long, deeply buried tunnels intersect water-rich fractured basalt. Single-method forecasting cannot resolve the spatial distribution of water-bearing structures or the progressive failure process. Using the Xianglu Mountain Tunnel as a case study, we propose a mechanism-analysis framework in which integrated geophysical prospecting provides priors for a Peridynamic (PD) numerical model. Specifically, Seismic ahead prospecting yields spatial distributions of elastic modulus, Poisson’s ratio, and density ahead of the face. Direct current resistivity delineates low-resistivity anomalies and, through an empirical resistivity–permeability relationship, enables quantitative inversion of the pre-excavation seepage field. These geophysical products are then injected as prior fields into a PD-based excavation–seepage failure model. The simulations indicate progressive damage of the confining rock layer (aquiclude) under multi-factor coupling until the damage zone coalesces and collapse occurs. Comparison with field observations shows close agreement in the predicted affected extent, demonstrating that the integrated approach explains collapse during excavation in water-rich basalt tunnels and provides a reliable pathway for advanced prevention and control of similar geohazards in deeply buried tunnels.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110581"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146025776","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 influence of water saturation state on the progressive failure characteristics in mudstone subjected stress loading","authors":"Jinghua Li ,&nbsp;Guichen Li ,&nbsp;Haoyu Rong ,&nbsp;Yaoqi Liu ,&nbsp;Zeyu Shao ,&nbsp;Bo Zhang","doi":"10.1016/j.engfailanal.2026.110607","DOIUrl":"10.1016/j.engfailanal.2026.110607","url":null,"abstract":"<div><div>Most studies on progressive failure in rocks have mainly focused on brittle materials, with limited attention given to mudstone, particularly regarding the effects of water. To address this gap, this study conducted mechanical tests on mudstone with varying water saturation, together with AE monitoring and SEM characterisation. The influence of water on physical state in mudstone was analyzed. The mechanisms by which water affects failure was revealed. The influence of water on progressive failure was discussed. Results indicate that, after water intruding mudstone develops tensile microcracks. Elastic modulus decreases linearly with saturation increasing. In mechanical tests, the proportion of AE tensile events and tensile cracking energy decrease linearly with water saturation, while plastic energy is the opposite. Macroscopic failure shifts from compressive shear to tensile rupture occurs with water saturation increasing. During the progressive failure process, crack initiation stress, crack damage stress, and peak stress all decreases exponentially with saturation increasing. While the uniformity of water distribution within the mudstone exerts a limited influence on both elastic modulus and <em>P</em>-wave velocity, it does effect on both stress threshold and progressive failure behaviour. After water intruding, the proportion of microcracking in elasto-plastic deformation stage (stage Ⅱ&amp;Ⅲ) increases 20% average. Failure to account for the increased cracking behaviour into the elasto-plastic stage, may lead to overestimation of the long-term bearing capacity of mudstone in engineering application where potential leakage is a concern. This study provided a new insight into the long-term stability of mudstone under water intruding and stress loading.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110607"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146170686","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 response and safety assessment of high-speed railway simply-supported beam bridge under rockfall impact","authors":"Gao Zhang,&nbsp;Chang He,&nbsp;LiZhong Jiang,&nbsp;Wei Guo","doi":"10.1016/j.engfailanal.2026.110623","DOIUrl":"10.1016/j.engfailanal.2026.110623","url":null,"abstract":"<div><div>This study systematically investigates the dynamic response and traffic safety performance of simply supported beam bridges on mountainous high-speed railways under rockfall hazards. By coupling rockfall trajectory simulation with refined finite element analysis, the study elucidates the damage evolution mechanism of bridge structures under rockfall impacts and the correlations among key parameters. The findings indicate that the dynamic response of superstructure components (including the track system, mortar layer, and sliding layer) is a strong correlation with pier displacement and exhibits higher damage sensitivity. Furthermore, an innovative bridge fragility model accounting for rockfall mass ranges is established, enabling quantitative assessment of the damage probabilities for piers, mortar layers, and sliding layers. Building upon this foundation, a method for evaluating train safety based on track geometric deformation after rockfall impact is proposed, identifying critical impact conditions at different operational speeds. This research provides theoretical support and technical references for the anti-impact design, safety protection, and operational decision-making of high-speed railway bridges in rockfall hazard environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110623"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075750","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 a centrifugal pump impeller in erosive flow conditions","authors":"Rehan Khan ,&nbsp;Moiz Ahmad ,&nbsp;Shahbaz Ali ,&nbsp;Faez Qahtani ,&nbsp;Tariq Talha ,&nbsp;Saeed Alqaed ,&nbsp;Jawed Mustafa ,&nbsp;Syed Osama Safdar","doi":"10.1016/j.engfailanal.2026.110584","DOIUrl":"10.1016/j.engfailanal.2026.110584","url":null,"abstract":"<div><div>Erosion is a critical factor that significantly reduces the service life of rotor blades in centrifugal pumps operating under sand particle-laden flows. In this study, a carbon steel blade from a submerged centrifugal pump experienced severe damage after only a few days of continuous operation at the Centre for Erosion-Corrosion Research. The most prominent damage was observed along the outer edges and raised guide vanes of the impeller blade, with localized wall thinning. To investigate the underlying failure mechanisms, a comprehensive analysis was conducted combining visual inspection, scanning electron microscopy (SEM), 3D surface scanning, energy-dispersive spectroscopy (EDS), and laser profilometry measurements. Numerical simulations were performed using computational fluid dynamics (CFD) coupled with the discrete phase model (DPM) to model particle-laden flow behavior and identify critical erosion zones. Unlike prior studies focused solely on simulation or idealized models, this work integrates real-world failure evidence with validated CFD-DPM modeling to establish a direct correlation between physical degradation and predicted erosion. The results revealed that erosion in high-impact regions was nearly twice as severe as in low-impact areas, primarily driven by high turbulence intensity and repeated impingement of 300 µm sand particles at flow velocities exceeding 5 m/s. A maximum erosion rate of 3.8 × 10⁻⁵ kg/m²·s was observed. This study provides new insights into the spatial relationship between flow-induced turbulence and material loss, contributing valuable data for improving pump blade durability and predictive wear modeling in abrasive fluid environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110584"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075809","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":"An interpretable random forest surrogate for rapid SIF prediction and fatigue life assessment of double-sided U-rib welds in orthotropic steel decks","authors":"Fanghuai Chen ,&nbsp;Benkun Tan ,&nbsp;Haitao Tang ,&nbsp;Haiping Zhang ,&nbsp;Yuan Luo ,&nbsp;Xinhui Xiao ,&nbsp;Yang Liu ,&nbsp;Naiwei Lu","doi":"10.1016/j.engfailanal.2026.110582","DOIUrl":"10.1016/j.engfailanal.2026.110582","url":null,"abstract":"<div><div>This paper presents an efficient predictive framework based on a random forest (RF) surrogate model for estimating fatigue crack propagation life in double-sided rib-to-deck (RD) welded joints in orthotropic steel decks (OSDs). A comprehensive training dataset for the RF surrogate model of stress intensity factor (SIF) was generated through extensive fatigue crack propagation simulations. The predictive accuracy of the RF surrogate model was rigorously validated, and SHAP-based feature analysis was employed to interpret the influence of input variables. The RF surrogate model was then used to estimate the fatigue life of the welded toe in double-sided RD welded joints, and the effects of initial crack geometry on fatigue life were investigated. The results indicate that the initial surface crack at the weld toe is a mode I-dominated mixed-mode crack and exhibits crack flattening during propagation. The RF surrogate model demonstrates high predictive accuracy for SIF, achieving high <em>R</em>² values and low prediction errors across both training and validation datasets. SHAP analysis identifies applied stress as the primary influencer of SIF, with crack depth and half-length as secondary factors. Increases in initial crack depth and half-length significantly reduce fatigue crack propagation life. This study confirms the robustness of the RF model as a computationally efficient alternative to finite element methods (FEM), providing valuable insights for fatigue assessment and maintenance planning of OSDs.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110582"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146025861","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 mechanical behavior and propagation mechanisms of rail cracks considering the influence of three-dimensional weld geometry","authors":"Jiaxin Lei ,&nbsp;Yangyong Luoze ,&nbsp;Haoyao Xia ,&nbsp;Jianing Liu ,&nbsp;Caiyou Zhao ,&nbsp;Ping Wang","doi":"10.1016/j.engfailanal.2026.110579","DOIUrl":"10.1016/j.engfailanal.2026.110579","url":null,"abstract":"<div><div>With the continuous increase in train operating speeds, rolling contact fatigue on rail surfaces has become a major concern, especially in welded regions where geometric irregularities and material mismatches intensify stress concentrations and accelerate crack growth. This study integrates ABAQUS and FRANC3D through a fracture-mechanics-based submodeling approach to simulate surface crack propagation in welded rails with realistic 3D weld geometry. The developed model clarifies how crack geometry and weld irregularities jointly affect fatigue behavior under rolling contact loads. The results indicate that surface cracks mainly propagate through a mixed Mode II–III shear mechanism. A 45° inclination angle represents the most critical propagation orientation. Increasing the surface crack length from 2 mm to 6 mm shortens fatigue life by 57.7%, while extending the crack length to 8 mm elevates the peak Mode III stress-intensity factor to 811 MPa, promoting inward growth. In the weld zone, the deeper crack front propagates faster, causing semicircular cracks to evolve into elongated ellipses. A strong interaction is observed between weld wavelength, depth and crack phase position: shorter wavelengths and deeper undulations markedly increase the Mode II stress-intensity factor, with the fastest propagation occurring at 3/8 of the weld wavelength—where fatigue life drops to 44% of that at 7/8 of the wavelength. The findings clarify the shear-dominated crack evolution mechanism and provide theoretical guidance for weld-grinding thresholds and fatigue-life assessment of welded rails in high-speed railway applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110579"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146001770","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":"Fatigue performance of Grade 10.9 M20 high-strength bolts in L-shaped component connections","authors":"Xu-Ze Feng,&nbsp;Xue-Chun Liu,&nbsp;Xuesen Chen,&nbsp;Wei Zhou,&nbsp;Yong-Li Tao,&nbsp;Ai-lin Zhang","doi":"10.1016/j.engfailanal.2026.110583","DOIUrl":"10.1016/j.engfailanal.2026.110583","url":null,"abstract":"<div><div>Bolted L-shaped component connections, which are typical configurations in bolted flange splicing joints for columns, are subjected to cyclic tension–compression from wind-induced vibration in high-rise buildings, leading to fatigue failure risks. To investigate the fatigue performance of Grade 10.9 M20 bolts, axial cyclic loading fatigue tests were conducted on 20 specimens with different flange thicknesses. Experimental results revealed that all fatigue failures occurred at the root of the first engaged thread or within the thread engagement region, with preload decay exceeding 30% prior to fracture. A refined finite element model incorporating thread was developed to conduct parametric analyses, demonstrating that the fatigue life significantly improves with increasing flange thickness, column wall thickness, bolt edge distance, and preload. Furthermore, a nominal stress calculation method accounting for bending-axial coupling effects was proposed, and an <em>S–N</em> curve describing the relationship between stress range and fatigue life was established with good fitting accuracy. Comparative analysis against fatigue design recommendations in EN 1993-1-9, ANSI/AISC 360-16, and GB 50017-2017 highlighted conservative predictions of the above codes. Macroscopic fracture morphology analysis of the high-strength bolts was carried out to further elucidate the fatigue failure mechanisms.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110583"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146025775","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 deformation and failure laws and differentiated control of surrounding rock in the return air entry of extremely close distance lower seam","authors":"Xiaofei Guo,&nbsp;Wenbo Zhang,&nbsp;Xiongxiong Jin,&nbsp;Kunlin Yang,&nbsp;Yinwei Wang,&nbsp;Yushan Liu","doi":"10.1016/j.engfailanal.2026.110557","DOIUrl":"10.1016/j.engfailanal.2026.110557","url":null,"abstract":"<div><div>Stability control of the surrounding rock in development roadways of extremely close-distance lower coal seams is a crucial prerequisite for safe mining in underground coal mines. This study aims to reveal the deformation and failure mechanisms of the surrounding rock in such roadways, taking the extremely close-distance No. 9 and No. 11 coal seams in Dianye No. 1 Mine as the research object. It elucidates the response mechanisms and failure patterns of roadways under such complex mining-induced stresses. The results indicate that the return airway of the No. 11 coal seam is primarily influenced by the mining of the No. 9 coal seam working face and its own excavation. In contrast, the mining of the working face within the same coal seam, due to the presence of protective coal pillars along the roadway, exerts a certain pressure-relief and protective effect on the corresponding roadway section. The study further reveals the evolutionary pattern of the plastic zone morphology in the surrounding rock and clarifies the correlation between stress variations and the plastic zone. The lateral pressure coefficient dominates the failure mode of the surrounding rock, while the magnitude of the principal stress and the strength of the rock mass jointly regulate the extent of failure. The deflection angle of the principal stress directs the propagation path of the plastic zone. A differentiated support design based on the stress zones of the surrounding rock is proposed. Under remnant coal pillars, a trapezoidal roadway section with rock bolting, mesh, and cable support is adopted to utilize the self-supporting capacity of the surrounding rock and the structural characteristics of the strata. In high-stress environments under goaf areas, a arched roadway section with combined support of “rock bolting, mesh, cable, beam, and U-shaped steel supports” is implemented.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"187 ","pages":"Article 110557"},"PeriodicalIF":5.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146025773","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}