Engineering Failure Analysis最新文献

{"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}

{"title":"Tensile deformation and fracture behavior at high temperature of the TLP joint for Hastelloy X superalloy with laminated interlayer","authors":"Taiyong Zou ,&nbsp;Zhenqian Lang ,&nbsp;Ruilong Lu ,&nbsp;Jiawei Liu ,&nbsp;Xianglai Xu","doi":"10.1016/j.engfailanal.2025.109363","DOIUrl":"10.1016/j.engfailanal.2025.109363","url":null,"abstract":"<div><div>Transient liquid phase diffusion bonding of Hastelloy X superalloy was performed using laminated foils of BNi-5 / BNi-5 and BNi-5 / Ni / BNi-5, respectively. A comprehensive analysis, combining experimental observations and crystal plasticity finite element analysis, was conducted to examine the microstructure, deformation, and fracture behavior of the joints. Both joints, bonded at 1170 °C for 4 h comprised an isothermal solidification zone (ISZ) and a diffusion affected zone (DAZ). The ISZ of the joint employing BNi-5 / BNi-5 exhibited columnar characteristics, with fine grains distributed on its flanks. During tensile testing, stress concentration arose at the ISZ-DAZ interface due to grain structure inhomogeneity. Furthermore, large size silicides were precipitated in the DAZ and at the the ISZ-DAZ interface. Under the stress concentration, cracks initiated at silicides and propagated along the interface, leading to a brittle fracture. The joint bonded with BNi-5 / BNi-5 possessed a tensile strength of 310 MPa and an elongation of 12.03 % at 750 °C, which amounted to 81.3 % and 32.5 % of the respective properties of the base material. The addition of Ni significantly increased the microstructure uniformity and inhibited the precipitation of silicides. The plasticity of the joint was improved and the fracture mode changed to intergranular ductile fracture. The tensile strength and elongation at 750 °C of the joint bonded with BNi-5 / Ni / BNi-5 were 305.4 MPa and 17.87 %, corresponding to 80.0 % and 48.2 % of the respective properties of the base material.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109363"},"PeriodicalIF":4.4,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143376687","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":"The mechanical properties and microscopic failure mechanism of fractured granite under fissure water pressure","authors":"Tingting Liu ,&nbsp;Lipan Cheng ,&nbsp;Zixu Wang ,&nbsp;Zi Wang ,&nbsp;Runchao Yang ,&nbsp;Luyang Ding ,&nbsp;Xinping Li","doi":"10.1016/j.engfailanal.2025.109393","DOIUrl":"10.1016/j.engfailanal.2025.109393","url":null,"abstract":"<div><div>The deep fractured rock mass undergoes damage and failure under the combined effects of high geostress and high permeability water pressure, leading to engineering geological disasters such as collapses and strong water inrush in underground projects. This study investigates the mechanical behavior of granite under fissure water pressure by conducting uniaxial compression tests on rock samples with varying crack inclinations using the RMT testing system. The Finite-Discrete Element Method (FDEM) was subsequently employed to examine the mechanism through which fissure water pressure affects the initiation and propagation of cracks in the rock mass. The results indicate that: (1) Under the influence of fissure water pressure, the peak strengths of specimens with varying fracture inclinations decreased by approximately 20% to 30%, while the acoustic emission signals decreased by 68% to 98%. (2) Based on the modified maximum tangential stress (MTS) criterion taking into account the <em>T</em>-stress, the calculation methods for crack initiation angle and crack initiation stress considering the rock fissure water pressure are derived. (3) The tensile effect on the wing cracks induces a rapid expansion of the fissure water pressure, while the secondary cracks are subsequently closed, thereby preventing further expansion of the water pressure. (4) The degree of fragmentation of the specimens was significantly lower than that of the standard cracked specimens. These specimens exhibited tensile failure parallel to the crack surface, shear slip along the crack surface, and tensile splitting failure perpendicular to the crack surface.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109393"},"PeriodicalIF":4.4,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395466","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":"Dealloying significantly improves the fatigue property of laser-welded joints of TC4 titanium alloy","authors":"Jian Long ,&nbsp;Lin-Jie Zhang ,&nbsp;Miao-Xia Xie ,&nbsp;Yong-Qiang Liu","doi":"10.1016/j.engfailanal.2025.109390","DOIUrl":"10.1016/j.engfailanal.2025.109390","url":null,"abstract":"<div><div>Titanium (Ti) alloys, characterized by the high specific strength, corrosion resistance, and non-magnetic nature, have been widely applied to the manufacturing of nuclear submarines, deep-diving submersibles, and aerospace equipment. Therein, TC4 is the most widely applied Ti alloy nowadays. The effects of incorporating pure Ti into the weld on the fatigue behaviors of laser-welded joints made from TC4 Ti alloy were studied. Experimental results demonstrate that the incorporation of titanium in the weld of butt joints enhances fatigue strength by 15%. The reduction in the microhardness gradient of joints is a significant factor contributing to the enhanced fatigue performance of laser-welded joints. The microhardness of the weld zone of TC4 laser welded joint was significantly reduced after Ti was added. Changes in the proportions of alloying elements and microstructures in the weld are important causes for the reduction of microhardness. Compared with the joints without addition of Ti, adding Ti can enlarge the size of acicular α′ martensite in the WM.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109390"},"PeriodicalIF":4.4,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378663","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":"Flow-induced corrosion of brass flowmeters used for drinking water","authors":"Luca Blanka Boncz ,&nbsp;Lotte Holmegaard ,&nbsp;Jens Lykke Sørensen ,&nbsp;John Hald ,&nbsp;Morten S. Jellesen","doi":"10.1016/j.engfailanal.2025.109394","DOIUrl":"10.1016/j.engfailanal.2025.109394","url":null,"abstract":"<div><div>Traditionally, water supply components were made of dezincification-resistant brass alloys due to their relatively low cost, good forging properties, and good machinability. However, due to recent legislation on the restrictions of lead and nickel, increased use of disinfection, and a more diverse range of flow conditions, corrosion failures have become more prevalent. This work describes the failure investigations of two domestic water flowmeters made of dezincification-resistant brass type CW511L, with a difference in internal diameter. The underlying cause of failure is determined by visual inspection, microstructural analysis with scanning electron microscopy, energy-dispersive X-ray spectroscopy, and corrosion product identification using X-ray diffraction. The scales formed at less degraded regions were identified as copper-enriched corrosion products mainly consisting of metallic elements, oxygen, and chloride, with most of the scale formation being malachite. Depletion of protective scales was seen in regions with high flow, resulting in flow-induced corrosion and high material losses. Computer fluid dynamics simulations confirm that specific regions were exposed to high flow rates, resulting in failure.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109394"},"PeriodicalIF":4.4,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395682","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":"Analysis of the failure mechanism of Thin-Walled grouting rings and optimization of uniform Open-Loop behavior","authors":"Chenghua Shi,&nbsp;Tao Zhu,&nbsp;Zhu Peng,&nbsp;Zixu Zhu,&nbsp;Xinyun Wen","doi":"10.1016/j.engfailanal.2025.109392","DOIUrl":"10.1016/j.engfailanal.2025.109392","url":null,"abstract":"<div><div>The application of refined grouting in complex urban underground spaces has unique advantages. The transition structure of the grouting ring can precisely control the direction of grout fracture, which is a key factor influencing the grouting effect. Optimizing the failure of the grouting ring structure is of significant importance for forming a stable grouting interface and reinforcing the surrounding strata. This study investigates the failure mechanism of thin-walled grout-stopping ring structures and analyzes the structural stress distribution under non-uniform in-situ stress conditions based on the elastic theory of thin-walled cylindrical structures. From the perspective of impact mechanics, an auxiliary ring-opening method using gravel aggregate impact is proposed. Field tests are conducted to validate the ring-opening mechanism and auxiliary mechanism. The results show that higher deviatoric stress increases the local failure stress σ_r4, which can lead to localized damage of the grout-stopping ring, resulting in grout seepage along a single direction and eventual ring failure. The impact method effectively assists the grout-stopping ring in reaching its failure limit uniformly, improving grout coverage by approximately 15.0% and reducing the probability of unidirectional failure, consistent with theoretical predictions. This research proposes structural design and process optimization recommendations for grout-stopping rings, providing theoretical and technical guidance for refined grouting applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109392"},"PeriodicalIF":4.4,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395681","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}