Engineering Failure Analysis最新文献

{"title":"Fatigue fracture behavior under thermal cyclic loads: Experimental methods, physical regularities, and damage mechanisms","authors":"Chenyu Du ,&nbsp;Haitao Cui ,&nbsp;Hongjian Zhang","doi":"10.1016/j.engfailanal.2025.109508","DOIUrl":"10.1016/j.engfailanal.2025.109508","url":null,"abstract":"<div><div>Thermal fatigue and creep-thermal fatigue are two typical fatigue fracture behaviors under thermal cyclic loads. This study focuses on three aspects. <em>i. Experimental methods.</em> A thermal cyclic experimental method suitable for thin-walled structures with holes was developed, and a tubular specimen with test holes was designed. By comparing different test hole configurations, it was found that the conical hole specimen shows the best performance in both crack growth and observation. <em>ii. Physical regularities.</em> Experiments were conducted with temperature range, mean temperature, and high-temperature hold time as the control variables. The influence patterns of these variables were empirically explained. The data demonstrated that the temperature range and high-temperature hold time are the main factors accelerating crack propagation. The increase in mean temperature reduced the fatigue life, but the effect was relatively weak. <em>iii</em>. <em>Damage mechanisms.</em> Microstructural observation and elemental analysis were conducted, and the damage mechanisms for both behaviors were summarized. The initiation and propagation of thermal fatigue cracks are primarily governed by fatigue behavior, with transgranular fracture as the dominant damage mode. Crack initiation in creep-thermal fatigue is still dominated by fatigue behavior. However, crack propagation is driven by the combined effects of creep, fatigue, and oxidation, resulting in intergranular fracture as the primary damage mode.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109508"},"PeriodicalIF":4.4,"publicationDate":"2025-03-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592034","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":"Data-driven investigation of elastoplastic and failure analysis of additively manufactured parts under bending conditions","authors":"Majid Shafaie ,&nbsp;Mohsen Sarparast ,&nbsp;Hongyan Zhang","doi":"10.1016/j.engfailanal.2025.109505","DOIUrl":"10.1016/j.engfailanal.2025.109505","url":null,"abstract":"<div><div>This study presents an advanced investigation the elastoplastic and failure behavior under bending condition applied to a Ti-6Al-4 V alloy part fabricated by Laser Powder Bed Fusion (LPBF) techniques. The objective is to develop a robust framework to accurately predict the material behavior of Ti-6Al-4 V alloy under bending loads by integrating the Finite Element Method (FEM), Deep Neural Networks (DNN), and Genetic Algorithms (GA) as an intelligent data-driven system. The prediction model incorporates many input components, including elastic modulus, Poisson’s ratio, Swift hardening model parameters, and modified GTN fracture model coefficients. The DNNs are trained using data generated from FEM simulations. Model evaluation is performed through k-fold cross-validation, ensuring robust performance assessment. GA are employed to optimize the coefficients of the elastic, plastic, and fracture models, minimizing the root-square normalized error (RSNE) between simulation results and experimental data. If the required error threshold is not achieved in an iteration, the process continues automatically, incorporating new data until the desired accuracy is reached. The findings demonstrate a successful characterization of elastic, plastic, and fracture-related properties, highlighting the capability of the proposed methodology to accurately predict the material behavior of components manufactured by various techniques under different conditions. This approach highlights the potential for extending the methodology to other materials and manufacturing processes, enabling precise prediction of material behavior in diverse applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109505"},"PeriodicalIF":4.4,"publicationDate":"2025-03-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611329","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":"Microstructural investigation into the damage mechanism of short pitch rail corrugation","authors":"Pan Zhang,&nbsp;Shaoguang Li,&nbsp;Fang Ren,&nbsp;Omid Hajizad,&nbsp;Rolf Dollevoet,&nbsp;Zili Li","doi":"10.1016/j.engfailanal.2025.109512","DOIUrl":"10.1016/j.engfailanal.2025.109512","url":null,"abstract":"<div><div>Short pitch corrugation is a typical rail defect that lacks a thorough understanding and adequate root-cause solutions. This paper aims to identify the damage mechanism of short pitch corrugation through a microstructural analysis of a field rail sample. This sample made of R260Mn pearlitic steel was taken from a straight section of the Dutch railway network, and its geometry and surface hardness variation along the corrugation were measured and analyzed. Eleven specimens, including both corrugated and non-corrugated zones, were sectioned from the rail sample and continuously examined using light optical microscopy, scanning electron microscopy and micro-hardness testing. The results indicate that the corrugation damage mechanism can be categorized into three stages: (1) pre-corrugation, characterized by uniform wear and plastic deformation; (2) corrugation initiation, dominated by differential wear; and (3) corrugation growth, involving both differential wear and plastic deformation accumulation. The initiation and growth of corrugation both contribute to an inhomogeneous distribution of plastic deformation layer (PDL) in the rail subsurface, which follows an approximately sinusoidal pattern, matching the corrugation geometry in both wavelength and phase. Consequently, the hardness also varies in phase with the corrugation geometry, with higher hardness values at corrugation peaks. In the non-corrugation zone, the PDL and hardness show relatively small and irregular fluctuations. This study also provides meaningful insights into rail grinding, suggesting that grinding should account for differential PDL thickness to prevent corrugation reoccurrence due to subsurface material inhomogeneity.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109512"},"PeriodicalIF":4.4,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611332","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":"Fatigue behaviour and S-N curve prediction of additively manufactured Inconel 718 using Self-Heating and Energy-Based methods","authors":"Martin Matušů ,&nbsp;Bastian Roidl ,&nbsp;Simon Amann ,&nbsp;Jakub Rosenthal ,&nbsp;Ivana Zetková ,&nbsp;Miroslav Zetek","doi":"10.1016/j.engfailanal.2025.109507","DOIUrl":"10.1016/j.engfailanal.2025.109507","url":null,"abstract":"<div><div>Inconel 718, a nickel-based superalloy, is extensively used in high-performance applications such as gas turbines, aerospace, and the nuclear and oil industries due to its exceptional fatigue resistance, corrosion resistance, and mechanical stability across a broad temperature range (−252 °C to over 700 °C). Its weldability and high-strength properties make it suitable for additive manufacturing (AM), particularly laser powder bed fusion (L-PBF). However, the dynamic properties of AM Inconel 718, influenced by surface roughness and microstructural variations, require thorough investigation. This study evaluates the mechanical properties of AM Inconel 718 in two build orientations produced using an EOS M290 printer. Static tests and hardness measurements were conducted to establish baseline properties. The fatigue behaviour was analysed using traditional S-N curve testing alongside a self-heating (S-H) methodology adapted from previous studies on AMed AlSi10Mg. The S-H method, focusing on temperature evolution during cyclic loading, was used to estimate the fatigue limit (FL) and S-N curve predictions. The LinExp method provided slightly conservative FL estimates, which served as lower thresholds for Fargione’s energy-based S-N curve model. Only two specimens per orientation were used, demonstrating its efficiency and resource-saving potential. This work underscores the viability of integrating innovative fatigue analysis techniques with traditional methods to optimize the design and evaluation of additively manufactured components.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109507"},"PeriodicalIF":4.4,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592038","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":"Partial damage to the hall during a heavy rainfall","authors":"Jacek Hulimka,&nbsp;Jan Kubica,&nbsp;Marta Kałuża,&nbsp;Rafał Krzywoń","doi":"10.1016/j.engfailanal.2025.109513","DOIUrl":"10.1016/j.engfailanal.2025.109513","url":null,"abstract":"<div><div>Among numerous causes of failures of large-format facilities, the loads caused by weather phenomena count among most frequent. Failures are typically caused by snow or wind load, while damage due to rainstorm is rarer. The study shows one such case when, after around 6 months of operation, part of the large-area roof of a production and storage hall collapsed. The failure occurred after 13 min of heavy rainstorm; however, the conducted analysis showed that the rain volume was within the ranges specified by the relevant standards. A detailed analysis was conducted of the design assumptions, structural calculations and the original design documentation, showing a number of design and construction errors, the effects of which compounded. The most critical error was the underestimation of the water load on the exterior sections of the roof, combined with too high roof attic and the absence of overflow scuppers. The result was a gradual failure involving the profiled sheet deck sections, followed by exterior purlins and expansion joint purlins, and some reinforced concrete columns. The study provides a detailed description of the failure, presenting the results of the authors’ own structural calculations and specifying the design and construction errors. The sequence of events of the failure is also reconstructed. Finally, the proposed recommendation are outlined.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109513"},"PeriodicalIF":4.4,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601404","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":"On the possibility of repairing super-exposed IN792 gas turbine blades","authors":"Ali Pourfathi,&nbsp;Mohammad Saeed Shahriari,&nbsp;Mohammad Amin Amjadi","doi":"10.1016/j.engfailanal.2025.109510","DOIUrl":"10.1016/j.engfailanal.2025.109510","url":null,"abstract":"<div><div>The blades in the turbine section of gas turbomachines experience high temperatures and, more importantly, mechanical loading stresses, which lead to blade microstructure degradation during service. Regarding this, one of the most economical techniques is to repair or refurbish these blades rather than replacing them with new ones. In the present work, the feasibility of repairing a stage of as-received super-exposed blades in the fourth stage of the turbine hot section is studied. Several samples are prepared from the as-received blades; afterward, a few samples are rejuvenated with standard heat treatment. Later, for both as-received and rejuvenated samples, metallurgical analysis of microstructure, such as optical microscopy and scanning electron microscopy, is performed. In addition, mechanical tests, such as high-temperature and room-temperature tensile tests, creep tests, and their fractography, are conducted. Finally, the results associated with both rejuvenated and as-received samples are compared with the minimum standard criteria provided by the original equipment manufacturer (OEM). It has been shown that the microstructure and mechanical properties of the as-received samples indicate that the blade is fully retired. Later, using the rejuvenation technique, the microstructure and mechanical behavior of the blades are restored not completely but favorably (around 30% recovery), and the lifetime of the rejuvenated blades can be extended for another working sequence.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109510"},"PeriodicalIF":4.4,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592035","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":"Safety risk to the timber roof structure of swimming pool halls after two decades of constant use","authors":"Jan Kubica ,&nbsp;Janusz Brol ,&nbsp;Karolina Kurtz ,&nbsp;Marek Węglorz","doi":"10.1016/j.engfailanal.2025.109509","DOIUrl":"10.1016/j.engfailanal.2025.109509","url":null,"abstract":"<div><div>This work presents a case study exploring the structural safety risk to the timber roof structures of the swimming pool halls in one of the oldest Polish water parks, which was built in 2001.</div><div>The superstructures of the roofs of these two swimming pool halls were made of glued laminated timber girders, in the form of two independent but similar structures with single-slope roofs. The superstructure consisted of main curved girders and straight intermediate girders with a span at the support axes of 25.0 m and a height at the ridge of approximately 11.3 m above floor level. The substructure of this roof structure consisted of continuous, multi-span (min. two-span) purlins, made from glued laminated timber, and single-span bracing purlins. The roof cover was laid on the purlins, and was made of 1.0 m wide sandwich panels consisting of an 80 mm thick polyurethane core and two sheet metal cladding layers. On the inside, the roof panels had an almost flat surface (with slight profiling), while on the outside, they had a<!--> <!-->trapezoidal shape. They were related to the use of insulated longitudinal joints. Two transverse joints of the roof sandwich panels were provided.</div><div>After two decades of constant service, numerous leaks and moisture stains were observed in both structural elements of the timber roof, due to roof leakage and incorrect hygrothermal behaviour of the roofing panels. Buckling of the sandwich roof panels caused this problem. The structure showed a lack of proper fastening of the purlins to the main and intermediate girders made of glued laminated timber, which could have led to the roof being lifted in the event of strong wind exposure (due to wind suction on the roof surface). This situation resulted in the need for a comprehensive assessment of the timber roof safety, rechecking of the load-bearing capacity of their structures, and the formulation of repair recommendations.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109509"},"PeriodicalIF":4.4,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592036","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 failure analysis of platform screen doors under subway aerodynamic loads using finite element modeling","authors":"Chengxing Yang ,&nbsp;Yujia Huo ,&nbsp;Kangpei Meng ,&nbsp;Wei Zhou ,&nbsp;Jun Yang ,&nbsp;Zhao Nan","doi":"10.1016/j.engfailanal.2025.109502","DOIUrl":"10.1016/j.engfailanal.2025.109502","url":null,"abstract":"<div><div>This study presents an investigation into the fatigue failure mechanisms of platform screen doors (PSDs) subjected to aerodynamic loads generated by high-speed subway trains. A comprehensive finite element model is developed, integrating with fast Fourier transform (FFT) techniques to isolate and evaluate pulsating wind frequencies that impact the structural behavior of PSDs. The extracted wind frequencies and transient vibration responses are analyzed to determine their effects on structural stability. A load-stress transmission model is introduced to convert aerodynamic load data into structural stress time histories, enabling detailed fatigue assessments. Additionally, a stress distribution model is constructed to capture variations in maximum stress under different train speeds and distances from the track centerline. The Brittle Cracking model is applied to assess potential damage to glass components, revealing that the wind load frequency remains significantly lower than the structure’s natural frequency, thereby preventing resonance-induced failure. To evaluate long-term performance, fatigue damage assessments of critical components (such as the bottom support, door frame, and bottom plate) are conducted using both Miner’s cumulative damage criterion and a nonlinear damage model based on fatigue driving force energy. The analysis demonstrates that the maximum equivalent damage values for these components are within safe limits over a 30-year design life, with values of 0.59, 0.06, and 0.27 for the linear model, and 0.65, 0.07, and 0.29 for the nonlinear model. The study concludes by proposing an optimized design for the bottom support structure, reducing structural damage by about 45%. This research provides innovative insights into improving the durability, safety, and performance of PSDs under dynamic aerodynamic loading, contributing both to theoretical advancements and practical applications in urban transit infrastructure.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109502"},"PeriodicalIF":4.4,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601405","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":"Repeated impact failure mechanisms in valve port for water hydraulic high-speed on/off valve: Experimental and numerical analysis","authors":"Lingkang Meng,&nbsp;Zhenyao Wang,&nbsp;Jiangxiong Li,&nbsp;Xianchun Jiang,&nbsp;Weican Wang,&nbsp;Yinshui Liu,&nbsp;Defa Wu","doi":"10.1016/j.engfailanal.2025.109503","DOIUrl":"10.1016/j.engfailanal.2025.109503","url":null,"abstract":"<div><div>Water hydraulic high-speed on/off valves (WHSVs) are critical components in digital water hydraulic systems due to their exceptional responsiveness and sealing performance. However, frequent high-speed impact on the valve port of the WHSV can lead to progressive seal failure, severely compromising system reliability. This study integrates experimental and numerical simulation results to reveal the impact failure mechanisms of the valve port of the WHSV. The changes in the leakage flow and morphology of the valve port under different numbers of impacts are analyzed by experiment. Meanwhile, an explicit dynamic finite element method is employed to simulate the stress and deformation behavior of the valve seat during impacts, which utilizes precise initial impact parameters derived from an accurate mathematical model of the WHSV, ensuring the reliability and accuracy of the simulation analysis. The experimental results show a significant increase in the leakage of the valve port with the number of impacts. Simulation results indicate that the equivalent plastic strain of the valve port increases with the number of impacts but ultimately tends to saturate. The inner chamfer sharp edge of the valve port is identified as the critical region for stress concentration and plastic deformation, as predicted by simulations and confirmed by experimental observations of fatigue-induced cracks and gaps. Comprehensive analysis results reveal that the root cause of the impact failure of the valve port lies in localized plastic deformation, enlarging the sealing contact area and thus reducing the sealing pressure. Moreover, cracks and gaps near the inner chamfer sharp edge increase the flow area of the valve port and aggravate leakage.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109503"},"PeriodicalIF":4.4,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579683","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":"Does printing direction influence the bond between 3D printed polymeric reinforcement and cementitious matrix?","authors":"Rowin J.M. Bol ,&nbsp;Yading Xu ,&nbsp;Mladena Luković ,&nbsp;Branko Šavija","doi":"10.1016/j.engfailanal.2025.109471","DOIUrl":"10.1016/j.engfailanal.2025.109471","url":null,"abstract":"<div><div>The use of 3D printed polymers in the form of lattice reinforcement can enhance the mechanical properties of cementitious composites. Methods like Fused Deposition Modelling (FDM) 3D printing enable their creation, but this process has a large (negative) effect on their mechanical properties, with a large dependency on the printing direction. Continuing on our previous study concerned with modelling the anisotropic behaviour of 3D printed polymeric reinforcement, this work focuses on the reinforcement-matrix bond. Because of the layer-by-layer filament extrusion process of the 3D printing technique, the edges of FDM 3D printed polymers are typically composed of ellipses. Based on this, it is hypothesized that morphological effects as a result of the 3D printing technique enhance the bond between 3D printed reinforcement and cementitious matrix: The elliptic geometry potentially facilitates interlocking with the cementitious mortar, thereby possibly enhancing the bond behaviour in certain directions. To investigate the geometrical directional-dependent features at the edges of 3D printed polymers in more detail, micro-scale models are developed. Geometrical effects induced by different printing configurations are studied. The simulation results are verified through meso-scale pull-out experiments. The interlocking effects as a result of the 3D printing technique show to be significant seeing a bond strength increase of up to 56<!--> <!-->% in one of the print configurations compared to the direction without any geometrical effects.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109471"},"PeriodicalIF":4.4,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143591443","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}