Engineering Failure Analysis最新文献

{"title":"Study on thermal fatigue damage mechanisms for high-speed train’s wheel-mounted brake disc considering multiaxial stress state","authors":"Jiacheng Shen ,&nbsp;Yu Pan ,&nbsp;Jianyong Zuo","doi":"10.1016/j.engfailanal.2025.109525","DOIUrl":"10.1016/j.engfailanal.2025.109525","url":null,"abstract":"<div><div>The wheel-mounted brake disc is a critical component of the high-speed train brake system, and the bolt hole is identified as a high-risk region for fatigue failure in practice. This study proposes a thermal fatigue damage analysis method incorporating the multiaxial stress state to explore the complex failure mechanisms for wheel-mounted brake discs. A finite element model of a typical wheel-mounted brake disc is established and validated for a closer-to-reality prognostication. The thermodynamic response of the brake disc during emergency braking is analyzed, and the fatigue life of the critical nodes is predicted based on the multiaxial stress state. The results reveal that the multiaxial stress in the bolt-hole region jointly contributes to the formation of fatigue damage, as opposed to being caused by a specific uniaxial one. Additionally, the evolution of fatigue crack propagation is further investigated by simulation analysis. The findings indicate that the propagation in axial is more likely to result in fatigue failure, compared to the radial direction. This study is supposed to provide insights into the mechanisms of thermal fatigue damage in wheel-mounted brake discs and offer guidance for the structural design of critical brake components as well as the development of effective maintenance strategies.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109525"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143620660","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 experimental study of high-velocity multiple impact on the structural behaviour of GFRP Cross-Ply laminates","authors":"Marco A. Paredes-Gordillo,&nbsp;Inés Iváñez,&nbsp;Shirley K. García-Castillo,&nbsp;Carlos Navarro","doi":"10.1016/j.engfailanal.2025.109522","DOIUrl":"10.1016/j.engfailanal.2025.109522","url":null,"abstract":"<div><div>This study examines the experimental behaviour of composite structures subjected to high-velocity multiple impact, which is critical in applications where simultaneous impacts from multiple projectiles or debris may occur. This work also investigates the influence of the distance between projectiles on global variables, including the damaged area. Furthermore, a comparison is conducted between single and multiple high-velocity impact. The findings reveal that both the damaged area, the ballistic limit and the residual velocity of the projectiles are significantly affected by the simultaneous multiple impact phenomenon.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109522"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628664","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":"Structural analysis of hybrid composite arms for light weight robots","authors":"Manchi Nageswara Rao ,&nbsp;Arockia Selvakumar Arockia Doss ,&nbsp;Daniel Schilberg","doi":"10.1016/j.engfailanal.2025.109520","DOIUrl":"10.1016/j.engfailanal.2025.109520","url":null,"abstract":"<div><div>Robot structures made of steel or aluminum tend to be heavy and can undergo significant deformation, which leads to increased power consumption and a higher risk of failure under load conditions. Therefore, it is essential to create lighter-weight structures without compromising the performance of the robot. Taguchi methods can be employed to design these lightweight robot structures and optimize their performance. Additionally, finite element analysis and machine learning can provide valuable insights into the behavior of these structures. A series of experiments have been designed and analyzed for hybrid composite tubes used in robotic arm applications, particularly focusing on fiber-reinforced polymer (FRP) materials wrapped around aluminum tubes. Filament winding is a well-known technique for applying FRP to tubes, and the primary approach in this investigation was analyzed using ANSYS Composite Pre/Postprocessor (ACP). The study investigates three models of hybrid composite pipes, varying the number of layers and the winding angle. Each model was subjected to cantilever loading at various node points, while keeping the wall thickness of the tube constant at 3 mm. The model with a CFRP winding angle of 45° and a layer thickness of 1.5 produced the best results compared to the others. It was observed that both the bending moment and shear stress of the tube increased with a rising winding angle, whereas the strain energy of the tube decreased with an increasing winding angle. The optimal winding angle was determined to be 45°. Additionally, the stresses on the filament-wound tubes under different load conditions were optimized, and a statistical analysis was conducted using Mini-Tab. The research further focused on identifying the maximum failure loading conditions for optimal parameters through composite failure analysis. The failure conditions of the composite tube under maximum sustainable parameters were compared with those of standard aluminum and CFRP tubes. The hybrid tube demonstrated less deformation and stress compared to the other models.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109520"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143631871","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":"Numerical study on temperature and thermomechanical rolling contact fatigue of polygonised wheel during tread braking","authors":"Yifei Luo,&nbsp;Changwen Tan,&nbsp;Zhijun Zhou,&nbsp;Gongquan Tao,&nbsp;Zefeng Wen,&nbsp;Wenjian Wang","doi":"10.1016/j.engfailanal.2025.109526","DOIUrl":"10.1016/j.engfailanal.2025.109526","url":null,"abstract":"<div><div>Wheel polygonization (polygonal wear) changes the wheel–rail contact and the wheel–brake shoe contact, which in turn changes the wheel temperature and the resulting rolling contact fatigue during tread braking. A simulation procedure based on the transient fully coupled thermomechanical finite element method is developed to investigate the response of the wheel material in the elastoplastic region, taking into account the synergistic effect of non-uniform thermal load and cyclic mechanical load due to wheel polygonization. The Dowling damage formula, Jiang–Sehitoglu fatigue model and Kapoor model are applied to investigate the rolling contact fatigue from the aspects of high cycle fatigue, low cycle fatigue and ratcheting failure, respectively. The temperature, stress–strain response, and fatigue pattern of a polygonised and a non-polygonised wheel during tread braking are compared. The simulation results show that wheel polygonization results in localized areas of low temperature at the troughs, while significantly higher temperature bands occur at the edges of contact hollows. Radial and circumferential compressive stresses and surface material flow increase as some stress–strain components tend to shakedown. Fatigue damage worsens especially at the polygonization crest, where the critical plane of crack initiation is more oblique to the axial direction and more towards the tread surface, while the ratcheting failure is attenuated. This research draws particular attention to polygonised wheels against excessive local temperature and rolling contact fatigue.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109526"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628562","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":"Research on fatigue crack propagation and fracture failure analysis of piston rod","authors":"Zhen Chen ,&nbsp;Nengpeng Chen ,&nbsp;Qiaomu Wang ,&nbsp;Qingjie Ran ,&nbsp;Chaocheng Wei ,&nbsp;Jun Tang ,&nbsp;Junhai Long ,&nbsp;Yuling Zhang","doi":"10.1016/j.engfailanal.2025.109523","DOIUrl":"10.1016/j.engfailanal.2025.109523","url":null,"abstract":"<div><div>The reciprocating compressors in underground gas storage (UGS) run under high temperature and high pressure for a long time, which leads to the piston rod bearing complex alternating load, easy to generate fatigue cracks and spread, and eventually lead to fracture failure, which seriously affects the safe operation of UGS. In this paper, the causes of piston rod fracture failure under actual operating conditions are studied by numerical simulation and test. Firstly, a finite element model is established based on the actual cyclic load of the piston rod, which is used as the boundary condition for crack propagation analysis. The crack propagation model is established by adaptive meshing method, and the stress intensity factor leading to crack propagation is determined by M−integral method. According to the fracture toughness of the piston rod material, the fracture failure occurs when the crack propagation length is 29.599 mm, and the fatigue crack propagation life extends with the decrease of the speed or the increase of the exhaust pressure. Secondly, the fracture morphology of the piston rod is analyzed, and the fracture type is determined to be fatigue fracture, and the crack source starts at the transition corner of the surface, which confirms the accuracy of the numerical simulation results. Long-term alternating load leads to stress concentration and initial crack. Metallographic analysis shows that excessive inclusion, abnormal organization and the presence of Se element are the main factors leading to fatigue fracture of the piston rod. The research results provide valuable insights and theoretical basis for fatigue failure problem and fatigue optimization design of piston rod, and have practical engineering guidance significance.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109523"},"PeriodicalIF":4.4,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628561","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":"Investigation on static and fatigue performance of CFRP/Al-alloy interference bolted joint considering the influence of hole-axis error","authors":"Caoyang Wang ,&nbsp;Hui Cheng ,&nbsp;Wenlong Hu ,&nbsp;Yuan Li ,&nbsp;Kaifu Zhang ,&nbsp;Yi Cheng","doi":"10.1016/j.engfailanal.2025.109516","DOIUrl":"10.1016/j.engfailanal.2025.109516","url":null,"abstract":"<div><div>Hole-axis error is one of the normal manufacturing errors during aircraft assembly due to non-uniform deformation caused by drilling, assembly force, and post-assembly positioning. This paper investigated the influence of hole-axis error on the static and fatigue performance of CFRP/Al-alloy bolted joints. Experimental investigations were carried out to evaluate the impact of hole-axis error (0.00 mm, 0.05 mm, 0.10 mm, and 0.15 mm) on static and fatigue performance of CFRP/Al-alloy interference bolted joints. The variation of hole-axis error within a certain range has a slight influence on the ultimate tensile strength of the joint. At the same time, the fatigue life increases at first and then decreases with the increase in the value of the hole-axis error. The hole-axis error introduces a pre-loading state of the bolted joint, which makes the material damaged in advance and decreases the structure stiffness. A scanning electron microscope (SEM) was used to observe the damage of holes. A modified fatigue life model was proposed to predict the fatigue life of CFRP/Al-alloy bolted joints with different hole-axis errors. A rational threshold for hole-axis error can be established, which is less than 0.15 mm (3 %). The results of this paper can provide corresponding guidance for the tolerance design of bolted joints with hole-axis error.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109516"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637313","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":"Optimizing hot tearing susceptibility of Mg-1Ca alloy by pulsed magnetic fields: Experimental investigation and numerical simulation","authors":"Xin Guo ,&nbsp;Yi Liu ,&nbsp;Hua Zhao ,&nbsp;Jiangfeng Song ,&nbsp;Jinge Liao ,&nbsp;Xiaohui Feng ,&nbsp;Bin Jiang ,&nbsp;Yuansheng Yang","doi":"10.1016/j.engfailanal.2025.109518","DOIUrl":"10.1016/j.engfailanal.2025.109518","url":null,"abstract":"<div><div>In this paper, the influence of pulsed magnetic fields (PMF) with different voltages (0 V, 50 V, 100 V, and 150 V) on the hot tearing susceptibility (HTS) of Mg-1Ca alloy was investigated, hot tearing experiments were carried out with a constraint rod casting (CRC) mold, and COMSOL simulations of the solidification process were performed. The experimental results showed that the HTS of the alloy decreased with increasing PMF voltage, and the alloy exhibited the lowest HTS at a PMF voltage of 150 V. The area of hot tears in hot spots was reduced from a complete fracture (∞) to 0.21 mm², and the cracking susceptibility coefficient (<em>CSC</em>_t) value decreased from 1.83 to 1.58. The application of PMF accelerates the passage through the susceptibility temperature range of hot tearing. Combined with the simulation results, it is shown that with the increase of PMF intensity, the forced convection of induced melt is enhanced, which leads to the breakage or separation of primary brittle dendrites and makes the grains more refined. It not only increases the tensile stress required for liquid film separation but also reduces the shrinkage strain acting on the grain boundary per unit. In addition, the electromagnetic force forcibly drives the melt to flow, which increases the flow velocity of the melt, thus enhancing the feeding ability of the alloy. Finally, the HTS of Mg-1Ca alloy was obviously optimized.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109518"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143631912","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 stress corrosion cracking of 316L stainless steel bend pipe in the atmospheric tower","authors":"Lei Chen ,&nbsp;Hejin Li ,&nbsp;Bingtao Qin ,&nbsp;Lida Wang ,&nbsp;Piji Zhang ,&nbsp;Wen Sun ,&nbsp;Hua Wang ,&nbsp;Zhengqing Yang ,&nbsp;Guichang Liu","doi":"10.1016/j.engfailanal.2025.109519","DOIUrl":"10.1016/j.engfailanal.2025.109519","url":null,"abstract":"<div><div>The top circulation system of the atmospheric tower maintains the fractionation balance inside the tower by refluxing and condensing the liquid. During operation, cracking and leakage occurred in the 316L stainless steel elbow of the recirculation line. A detailed failure analysis was conducted through experimental testing, along with stress analysis and fluid flow simulations. The results showed that a small amount of water in the gasoline tends to accumulate on the outer side of the elbow under the effects of by centrifugal forces, creating a chloride and sulfur corrosive environment. The inner wall of the elbow underwent localized pitting corrosion due to the combined effects of welding thermal influence and chloride ion corrosion, resulting in the formation of numerous corrosion pits. Under the influence of external tensile stress and welding residual stress, these corrosion pits served as crack initiation sites and gradually propagated, ultimately leading to leakage failure. This failure was the result of the combined action of multiple factors, including welding residual stress, corrosive environment, and external loading. Based on the failure analysis, a series of targeted protective measures were proposed as well.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109519"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611333","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":"Multifactorial prediction of corrosion fatigue crack growth in aluminum alloys using physics-informed neural networks","authors":"Tianhao Huang ,&nbsp;Xueyuan Li ,&nbsp;Yongzhen Zhang ,&nbsp;Leijiang Yao ,&nbsp;Tao Zhang","doi":"10.1016/j.engfailanal.2025.109521","DOIUrl":"10.1016/j.engfailanal.2025.109521","url":null,"abstract":"<div><div>In-service corrosion fatigue cracking in aluminum alloy structural components poses a significant threat to the structural integrity of aircraft, making accurate crack propagation prediction essential for both safety and maintenance planning. Traditional machine learning models, such as Random Forest, Extreme Gradient Boosting (XGBoost), and Artificial Neural Network (ANN), rely primarily on data-driven methods and often neglect the underlying physical mechanisms, resulting in reduced prediction accuracy in complex environments. To overcome this limitation, physics-informed neural network (PINN) is used, which integrate physical laws (the Walker crack growth model) with data-driven learning. This hybrid approach effectively captures critical factors that influence crack propagation, such as initial crack length, stress ratio, and environmental conditions (e.g., pH, temperature, and chloride ion concentration). By embedding physical knowledge into the network, PINN significantly improves both the accuracy and generalizability of crack growth prediction. Experimental validation on various aluminum alloys, including 2024, 7075, and LY12, demonstrates that PINN outperforms traditional models, achieving higher prediction accuracy and faster convergence. The study underscores the potential of PINN for crack growth prediction, advancing fatigue life prediction and contributing to improved safety and durability of aircraft components.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109521"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611336","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 by keyway stress concentration of a pickling decoiler machine output shaft","authors":"Pedro R. da Costa ,&nbsp;M. Freitas","doi":"10.1016/j.engfailanal.2025.109515","DOIUrl":"10.1016/j.engfailanal.2025.109515","url":null,"abstract":"<div><div>In July 2021, an intervention and fracture analysis were conducted following the failure of a shaft in a pickling decoiler box machine. Mechanical hardness and chemical composition measurements, performed in the owner’s laboratories, revealed that the shaft was made of low-alloy steel containing chromium (Cr) and molybdenum (Mo), similar to 42CrMo4 (DIN standard) or 4140 (AISI standard), quenched and tempered. Close inspection of the fracture surface indicated that failure originated from rotating bending efforts. The combination of the rotary bending stresses with two stress concentration effects − one due to a keyway and another due to a diameter transition −resulted in localized stresses exceeding the material’s estimated fatigue endurance. The resulting high local stress caused multiple fatigue crack initiation points along the shaft perimeter, leading to progressive crack growth and eventual failure. Finite element analysis characterized the two stress concentration factors, revealing that the keyway had the most significant impact. To address the issue, an in-depth analysis of the keyway’s bending stress concentration factor and the associated stress distribution was conducted, culminating in the proposal of a new keyway location and geometry.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109515"},"PeriodicalIF":4.4,"publicationDate":"2025-03-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592037","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}