Engineering Failure Analysis最新文献

{"title":"Simulation-driven estimation of stiffness and damping coefficients using Sommerfeld curves for vibration reduction in induced draft fans","authors":"Erick-Alejandro González-Barbosa ,&nbsp;Jose-Juan Vázquez-Martínez ,&nbsp;Gerardo Trejo-Caballero ,&nbsp;Hector Castro-Mosqueda ,&nbsp;Fernando Jurado Pérez ,&nbsp;Alfonso Ramírez-Pedraza ,&nbsp;José-Joel González-Barbosa","doi":"10.1016/j.engfailanal.2026.110578","DOIUrl":"10.1016/j.engfailanal.2026.110578","url":null,"abstract":"<div><div>Computer modeling and simulation are important tools used for solving problems in engineering applied to industry. Proper modeling and simulation testing of the systems under analysis allow for design adjustments before manufacturing, which leads to reductions in time and costs. This project conducts a comprehensive analysis aimed at mitigating excessive vibration in two induced draft fans operating in a thermoelectric power plant. The tools used for the analysis include instrumentation through accelerometers, estimation of stiffness and damping parameters by the Sommerfeld methodology, as well as computer modeling and simulation. The instrumentation enabled estimation of the rotor’s natural frequencies, validated through computer simulation. Finite element analysis (FEA), guided by the Sommerfeld methodology, enhanced simulation accuracy. Sommerfeld curves, reconstructed from low-resolution 1965 printed sources (original digital data unavailable), were digitized and subsequently reconstructed using the Smoothing Spline algorithm for continuous and coherent profiles. At the end of this study, we present a redesign solution, validated through computer modeling and simulation, to reduce excessive vibration in two induced draft fans of a thermoelectric power plant.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110578"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145972854","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":"Peridynamic simulation on crack propagation and mechanical properties of tunnel linings with cracks","authors":"Yuqiang Pan ,&nbsp;Xiaokai Niu ,&nbsp;Wei Li ,&nbsp;Zixian Jin ,&nbsp;Kun Huang ,&nbsp;Jie Su ,&nbsp;Chengping Zhang","doi":"10.1016/j.engfailanal.2026.110561","DOIUrl":"10.1016/j.engfailanal.2026.110561","url":null,"abstract":"<div><div>Crack propagation critically threatens the structural integrity of urban underground tunnel linings. This study employs an integrated experimental and numerical methodology, combining scaled model tests with peridynamic (PD) simulations, to investigate cracking mechanisms and quantify the effects of pre-existing cracks in a case study of Beijing Subway Line 1. The complete cracking process, internal force redistribution, and ultimate failure modes are analyzed. Results identify a sequential failure pattern: cracks initially initiate at the invert, subsequently appear at the crown, and then interconnect at the springlines, ultimately leading to structural collapse. Pre-existing cracks are shown to significantly degrade structural stiffness and bearing capacity, with severity increasing with crack depth. Specifically, a crack depth of half the lining thickness reduces the ultimate bearing capacity by 24 %–26 % at the crown and up to 30 % at the invert. This work validates the PD method for tunnel fracture analysis and assessing the safety of tunnel linings.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110561"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973285","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":"Durability assessment of UHPC with varying steel fiber contents under sulfuric acid Attack: Macro-Micro characterization","authors":"Jie Xiao ,&nbsp;Jiajie Liu ,&nbsp;Ruiqian Liang ,&nbsp;Lingfei Liu ,&nbsp;Jiahui Feng ,&nbsp;Zhaoxiang He ,&nbsp;Xiyuan Chen ,&nbsp;Haibo Jiang","doi":"10.1016/j.engfailanal.2025.110523","DOIUrl":"10.1016/j.engfailanal.2025.110523","url":null,"abstract":"<div><div>This study investigates the degradation mechanisms and mechanical performance evolution of ultra-high-performance concrete (UHPC) exposed to sulfuric acid environments (pH≈0.9) through accelerated immersion tests. The influence of steel fiber content (0 %, 1 %, and 2 %) on UHPC’s deterioration behavior was systematically evaluated using X-ray diffraction (XRD) and scanning electron microscopy (SEM). Experimental results revealed a characteristic mass variation pattern: initial mass gain followed by gradual loss, with higher fiber content specimens exhibiting lower mass change rates due to enhanced corrosion layer spalling. The corrosion depth increased with exposure duration but showed significant retardation after 60 days, demonstrating steel fibers’ effectiveness in reducing penetration. Mechanical characterization indicated progressive deterioration of compressive strength, elastic modulus, flexural strength, and axial tensile strength, with rapid initial degradation followed by stabilization. Steel fiber incorporation significantly improved corrosion resistance coefficients, confirming their beneficial role in acid exposure conditions. The susceptibility of mechanical properties to sulfuric acid attack followed the order: tensile strength &gt; flexural strength &gt; compressive strength. Microstructural analyses identified gypsum as the predominant corrosion product, whose accumulation in matrix pores generated detrimental internal stresses. XRD patterns demonstrated decreasing gypsum peak intensities with sampling depth, while steel fibers effectively inhibited corrosion product formation. The strong correlation between microstructural observations and macroscopic performance degradation provides fundamental insights for durability assessment of UHPC in aggressive sulfuric acid environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110523"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973374","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effects of aged mortar on mechanical behavior of recycled aggregate Concrete: Experimental Tests, Microplane-Based mesoscale simulation and design Implications","authors":"Lang Lin ,&nbsp;Nuo Xu ,&nbsp;Di Yang ,&nbsp;Yiming Xiao ,&nbsp;Yong Yu","doi":"10.1016/j.engfailanal.2025.110521","DOIUrl":"10.1016/j.engfailanal.2025.110521","url":null,"abstract":"<div><div>Recycled aggregate concrete (RAC) offers clear environmental benefits, yet its heterogeneous internal structure limits broader application. Conventional tests cannot isolate key factors such as the amount and spatial distribution of adhered (aged) mortar. To address this, a mesoscale simulation framework is developed to quantify their influence on RAC’s mechanical behavior. RAC is idealized as a six-phase composite and modeled with a microplane formulation capable of capturing damage evolution, crack initiation and growth, and tension–compression responses while reducing mesh sensitivity. After validation against experiments, parametric analyses were conducted to clarify the roles of adhered-mortar characteristics. The main conclusions are: (a) The model accurately reproduced RAC’s tensile and compressive behavior, including damage patterns, crack evolution and axial–lateral deformation. (b) When new and old mortar had equal strengths, increasing adhered mortar content (0–100%) reduced compressive strength, elastic modulus and tensile strength, with the smallest drop in tensile strength. (c) A uniform coating of old mortar around recycled aggregates lowered uniaxial strength compared with a scattered distribution, with little effect on elastic modulus. (d) With the same average aged-mortar strength, a wider strength variation among aged-mortar phases further decreased RAC strength.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110521"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145895822","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":"Evaluation of the rock-cutting performance for TBM partial-wear cutters using vibration analysis and discrete element method","authors":"Yue Li ,&nbsp;Heng Xie ,&nbsp;Gongbo Zhou ,&nbsp;Yan Zhang","doi":"10.1016/j.engfailanal.2025.110512","DOIUrl":"10.1016/j.engfailanal.2025.110512","url":null,"abstract":"<div><div>Partial wear of disc cutters significantly affects the operational efficiency of tunnel boring machines (TBMs), highlighting the importance of accurate wear evaluation. This study develops a multi-indicator evaluation framework integrating vibration analysis and the discrete element method (DEM) to assess the rock-cutting performance of partial-wear disc cutters. Vibration signals are processed using Fourier transformation and Complete Ensemble Empirical Mode Decomposition with Adaptive Noise (CEEMDAN). In addition, DEM simulations are employed to elucidate the rock-breaking mechanisms of partial-wear cutters within a multi-cutter cutterhead system and to interpret the corresponding vibration characteristics. Key findings include: (1) Three quantitative indicators, including Root Mean Square (RMS), Frequency Coefficient of Variation (FCV), and Fuzzy Entropy (FuzzyEn), are able to effectively characterize vibration patterns across different wear levels. With increasing partial wear, RMS and FCV rise, whereas FuzzyEn decreases. (2) With increasing partial wear, the increased sliding friction strengthens dynamic coupling between the cutter and cutterhead, supporting the feasibility of real-time wear monitoring via cutterhead-mounted accelerometers. (3) DEM results indicate that the rock fragmentation process by a partial-wear cutter is no longer dominated by rolling and crushing but by sliding-dominated process.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110512"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921357","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":"Wear failure analysis of copper alloy connecting rod bearing of high-pressure seawater plunger pump in deep-sea environment","authors":"Jie Dong ,&nbsp;Yinshui Liu ,&nbsp;Chenlei Su ,&nbsp;Xianchun Jiang ,&nbsp;Yipan Deng ,&nbsp;Defa Wu ,&nbsp;Zhenyao Wang","doi":"10.1016/j.engfailanal.2026.110531","DOIUrl":"10.1016/j.engfailanal.2026.110531","url":null,"abstract":"<div><div>The lubrication failure and wear of connecting rod bearings are typical fault forms of the transmission components in high-pressure seawater plunger pumps. Different from traditional pumps that work on land, the additional compensating pressure in the deep-sea environment changes the force state of the connecting rod, thereby increasing the risk of failure. The connecting rod bearings used at 2000 m depth exhibited severe wear, with obvious oil oxidation and black carbon deposits. The main wear mechanisms have been confirmed to be adhesive wear and oxidative wear through macroscopic and microscopic examination. To investigate the wear failure, a coupled model of multi-flexible body dynamics (MFBD) and thermo-elasto-hydrodynamic (TEHD) based on flexible linkages was developed, which can accurately obtain the lubrication parameters under different working conditions, including oil film pressure, thickness, bearing deformation, friction thermal load, and wear depth. The influence of the deformation behavior and scraping resistance of connecting rods on wear depth and oil film temperature was investigated, and the formation mechanism of high-temperature oxidation of lubricating oil film and wear surface morphology was analyzed. The results indicate that under deep-sea tensile loading, material segregation and insufficient yield strength cause connecting rod deformation and subsequent scraping. This deformation accelerates wear by altering the oil film geometry, while the associated frictional heating raises the interface temperature, leading to oxidative wear on the bushing surface.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110531"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921796","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":"UV–Thermal degradation and failure mechanisms of hybrid Basalt/Glass Fibre reinforced polymer laminates for structural applications","authors":"Sheeraz Ali ,&nbsp;Jianxun Liu ,&nbsp;Hirwa Nshuti Roger ,&nbsp;Furqan Ahmed ,&nbsp;Mutahar Ali ,&nbsp;Innocent Chikira Msangi ,&nbsp;Heping Wu ,&nbsp;Zhishen Wu","doi":"10.1016/j.engfailanal.2025.110479","DOIUrl":"10.1016/j.engfailanal.2025.110479","url":null,"abstract":"<div><div>Fiber-reinforced polymer composites used in outdoor applications face significant degradation due to prolonged UV exposure and temperature variations, leading to reduced mechanical performance and service life. To examine this issue, this paper presents the results of an experimental study to determine the potential for the utilization of hybrid basalt/glass fabric layer arrangements at several UV durations. The composite laminates were manufactured using the hot compression molding process and subjected to tensile testing at 25 °C, 40 °C, and 60 °C after 500, 1000, and 1500 h of UV resistance. The laminate G₁₂ showed the most degradation, whereas G₀B₁₂, G₂B₁₀, and G₄B₈ showed minor degradation or were mostly unchanged when the UV duration and temperature were increased above room temperature. Laminates with a higher proportion of basalt fiber (BF) performed better than those with a higher percentage of glass fiber (GF), particularly when the outer layer was made of basalt fiber, which improved performance and prolonged UV resistance. However, after prolonged UV protection, the tensile strength and elastic modulus of all the laminates dropped noticeably.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110479"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880840","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 the influence of contact zone dip angle between soft and hard rocks on tunnel surrounding rock failure mechanism","authors":"Haijun Yu ,&nbsp;Zhigang Tao ,&nbsp;Yonghong Wu ,&nbsp;Changyi Yu ,&nbsp;Shusen Huo ,&nbsp;Hong Wei ,&nbsp;Hanqian Weng","doi":"10.1016/j.engfailanal.2025.110501","DOIUrl":"10.1016/j.engfailanal.2025.110501","url":null,"abstract":"<div><div>The contact zone between soft and hard rocks significantly impacts tunnel stability due to its mechanical heterogeneity and varying dip angles, which can lead to tunnel collapse. In this study, combined with laboratory test, theoretical analysis, field monitoring and FLAC-PFC coupling numerical simulation method, the response of surrounding rock during tunnel excavation is analyzed in depth. The results show that the uniaxial compressive strength ratio between soft and hard rocks is approximately 7, with failure predominantly occurring on the soft rock side. As the dip angle increases from 0° to 90°, failure modes transition from tensile-dominated to shear slip parallel to the dip angle. In the low inclination angle (0°–30°), the accumulation of slip energy is relatively slow, while in the high inclination angle (45°–90°), the accumulation of slip energy is significantly accelerated, highlighting the dominant role of dip angle in shear failure and energy dissipation. The coupled simulation effectively reproduces the overall response of the surrounding rock and provides reliable theoretical and practical support for tunnel construction and support design under similar geological conditions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110501"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880841","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 wheel damage of heavy-haul locomotive subjected to longitudinal coupler forces: Formation mechanism and control measures from macro insight","authors":"Qinghua Chen ,&nbsp;Qian Xiao ,&nbsp;Shiqian Chen ,&nbsp;Xiangrui Ran ,&nbsp;Xiaoyu Hu ,&nbsp;Yang Jin ,&nbsp;Binjie Xu ,&nbsp;Kaiyun Wang","doi":"10.1016/j.engfailanal.2025.110482","DOIUrl":"10.1016/j.engfailanal.2025.110482","url":null,"abstract":"<div><div>The distribution of wheel damage of locomotives subjected to longitudinal coupler forces in heavy-haul trains has not yet been fully understood. Field tests confirm that longitudinal compressive coupler forces are commonly present in scenarios in which the train brakes through long downhill slopes, typically where locomotives are prone to wheel damage. This study employs a wheel damage prediction model based on a comprehensive train dynamics simulation to systematically investigate the influence of train braking operations on the dynamic response of locomotives and the distribution of wheel damage. The braking performance and wheel damage under various slopes and control modes are analyzed, and a feasible boundary for braking control is identified to mitigate wheel damage. Furthermore, two damage control schemes based on the differential distribution of electric braking forces are proposed. Simulation results indicate that coupler forces exacerbate wheel damage on slave control locomotives by affecting the axle load transfer of locomotives and demonstrate that the proposed scheme could effectively suppress longitudinal impulses and control wheel damage. These findings establish a foundational framework for implementing braking control modes that actively reduce wheel damage in locomotives of heavy-haul trains.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110482"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880845","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 mechanisms and reliability assessment of MgO-based TMR sensors under harsh electrical and environmental conditions","authors":"Guanying Wang,&nbsp;Xianfeng Liang,&nbsp;Yuxin Cheng,&nbsp;Yixue Wang,&nbsp;Yang Lu,&nbsp;Dengfeng Ju,&nbsp;Jinghong Guo","doi":"10.1016/j.engfailanal.2025.110473","DOIUrl":"10.1016/j.engfailanal.2025.110473","url":null,"abstract":"<div><div>This study presents a comprehensive long-term reliability evaluation of MgO-based TMR current sensors under combined electrical and environmental stress conditions representative of smart grid environments. We subjected packaged sensors to a suite of accelerated stress tests (stepwise voltage ramp-to-breakdown, high-temperature operating life, biased damp-heat exposure, thermal cycling, electrostatic discharge, and surge events). We continuously monitored the sensors’ electrical output during each test and complemented these measurements with infrared thermography and post-test failure analysis. Each stress produced a distinct failure signature. Excessive voltage stress induced an abrupt dielectric breakdown of the MgO tunnel barrier, resulting in a sudden drop in the device’s resistance and localized melting. Under combined high-temperature and high-humidity stress, moisture ingress caused a gradual increase in leakage current, eventually leading to a short-circuit through edge-initiated pinholes. In contrast, high-temperature operation alone caused only modest parameter drift with no catastrophic failures, indicating good intrinsic thermal stability of the magnetic tunnel junction (MTJ) stack. Thermal cycling primarily affected the package interconnects, while the MTJ devices remained intact. On-chip protection clamps largely absorbed fast transient surges; in some cases, the clamps themselves short-circuited yet still successfully protected the MTJ core. Overall, device reliability is governed by the integrity of the MgO barrier and the robustness of the packaging and protection circuitry. Electrical overstress and moisture emerged as the dominant failure drivers, whereas elevated temperature and thermomechanical cycling induced much slower and more manageable degradation. This analysis correlates each stressor with its underlying failure mechanism and outlines practical mitigation measures. Key recommendations include voltage derating, robust transient-clamping circuitry, moisture-resistant packaging, high-temperature-stable MTJ stacks with an appropriate annealing burn-in process, and a compliant interconnect design. Implementing these measures will enable durable, field-ready TMR sensors and facilitate predictive maintenance. To the best of our knowledge, this study presents the first comprehensive reliability evaluation of TMR sensors under combined stress conditions. It addresses a critical knowledge gap and offers actionable design guidelines for robust sensor deployment.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110473"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837491","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}