Engineering Failure Analysis最新文献

{"title":"Failure intervention of transmission line tower primary legs using bi-angled cruciform retrofitting","authors":"Gorripotu Kishorekumar,&nbsp;Raghavan Ramalingam","doi":"10.1016/j.engfailanal.2024.108970","DOIUrl":"10.1016/j.engfailanal.2024.108970","url":null,"abstract":"<div><div>Retrofitting has been suggested by researchers as an intervention measure against failure of transmission towers which needs to be done with minimal disruption. Retrofitting of the primary leg members of transmission line towers by bi-angled cruciform arrangement has been shown in literature to be effective. However, the influence of stresses and deformations existing in the leg member prior to retrofitting on the capacity of the final retrofitted member is not known. Therefore, this study assesses the effectiveness of bi-angled cruciform sections under preload conditions through experiment followed by a numerical study. The level of preload in the primary leg member with respect to its theoretical capacity, slenderness ratio and width-thickness ratio of the angle section were the parameters. The results suggest that bi-angled cruciform retrofit is more effective at lower slenderness and width-thickness ratios and the reduction in capacity of retrofitted member is more noticeable till 50 % preload after which the changes are not significant. While the former two parameters lead to lower load share in the retrofitting member, higher preloads however lead to more equal load share. The application of this retrofitting pattern is demonstrated numerically with a full-scale tower model simulated under code specified load cases. Critical load cases leading to tower failure before design loads were identified and the retrofitting was incorporated into the model for these load cases. The analysis showed that the final loads attained in these load cases improved by upto 70 % thus confirming the potential of this retrofitting technique in preventing tower failure.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142445222","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental and numerical investigation on progressive collapse resistance of three-dimensional RC structures","authors":"Mengxue Guo ,&nbsp;Hua Huang ,&nbsp;Shilin Yang ,&nbsp;Min Huang","doi":"10.1016/j.engfailanal.2024.108954","DOIUrl":"10.1016/j.engfailanal.2024.108954","url":null,"abstract":"<div><div>An investigation on progressive collapse for three-dimensional RC structures was presented in this paper, based on a series of experimental tests and numerical analysis. The crack pattern and load–displacement curves were compared and discussed according to three single-story specimens under the loss of corner column and a two-story specimen under the loss of edge column. Experimental results show that flexural action is the main resistance mechanism for specimens whether the removal of corner or edge column. Moreover, the effect of the slab and secondary beam on the loading transfer mechanism was studied based on finite element model with various scenarios established by ABAQUS. The numerical results had a well agreement with the experimental results. FEA results indicated that the phenomenon of uneven distribution of loads can be improved due to the existence of slab and secondary beam. Finally, the corresponding analytical models considering the effect of secondary beam and torsion of primary beam with various scenarios were proposed to predict progressive collapse resistance.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142433227","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 of blast furnace tuyeres and mitigation strategies: A comprehensive review","authors":"Namballa Baby Raga Malikasri ,&nbsp;Kaushal Kishore ,&nbsp;Kanwer Singh Arora ,&nbsp;Girija Shankar Mahobia","doi":"10.1016/j.engfailanal.2024.108968","DOIUrl":"10.1016/j.engfailanal.2024.108968","url":null,"abstract":"<div><div>Iron blast furnace is a gigantic counter-current reactor and contributes to the majority of ∼1.9 billion tonnes of steel produced annually. Among various components of the blast furnace, tuyeres made of high-purity copper with protective coatings are the most critical in nature from the viewpoint of smooth furnace operation without interruptions. These water-cooled copper tuyeres inject preheated blast between 1200–1300 °C into the furnace for oxidation of coke and subsequent reduction of iron ore from the gaseous reductants. In the present review article, different failure mechanisms of the tuyeres are clarified, and the underlying reasons are stated from the viewpoint of the manufacturing aspects of the tuyeres, its design and application of coatings, operational effects and the quality of raw materials being used in the blast furnace. Predominant failure mechanisms include melting loss due to slag and liquid iron, erosion caused by pulverized coal, thermal fatigue exacerbated by the metallurgical segregation and heterogeneities within the coatings, Zn-diffusion induced Brass formation and subsequent deterioration due to reduced thermal conductivity and chloride induced corrosion cracking. A state-of-the-art review of various strategies for improved reliability and service life of Cu tuyere and way forward for further research is proposed in this work. It is expected to benefit the blast furnace operations as well as failure analysts and researchers working to improve the reliability of the tuyeres and other components made of Cu.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442285","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":"Steel-based brake disc laser cladding coating preparation method and brake performance study","authors":"Yongsheng Zhao ,&nbsp;Yan Liu ,&nbsp;Ying Wu ,&nbsp;Zhenlin Zhang ,&nbsp;Jin Liu ,&nbsp;Shao Xie ,&nbsp;Lin Deng ,&nbsp;Chao Ge ,&nbsp;Chunlun Chen ,&nbsp;Hui Chen","doi":"10.1016/j.engfailanal.2024.108962","DOIUrl":"10.1016/j.engfailanal.2024.108962","url":null,"abstract":"<div><div>In recent years, as the operating speed of high-speed trains has continued to increase, the thermal load challenges faced by brake discs during emergency braking have become more severe. Applying surface strengthening techniques to create high-performance coatings on the friction surface of brake discs is crucial for enhancing their thermal fatigue resistance and extending their service life. This study focuses on a 1:1 scale model of a steel-based brake disc for high-speed trains, using Stellite 21 cobalt-based alloy powder as the coating material. High-performance coatings were successfully prepared on the surface of the brake disc using laser cladding technology. A high-speed railway brake dynamometer test, ranging from 50 to 400 km/h, was conducted to validate the method for preparing the laser cladded brake disc (LC-disc). The prepared LC-disc exhibited good forming quality, with no defects such as cracks, pores, or incomplete fusion detected through non-destructive testing, and a powder utilization rate of over 80 %. The microstructure of the coating primarily consisted of the γ-Co phase, with minor amounts of ε-Co and M₇C₃. After the braking dynamometer test, columnar grains in the coating underwent deformation or recovery recrystallization, leading to grain refinement. During braking, the LC-disc demonstrated a stable coefficient of friction (COF), ranging between 0.296 and 0.44. The COF decreased with increasing initial speed and bilateral pad thrust, and was lower under wet conditions and higher pad thrust, indicating the LC-disc’s suitability for higher speeds and more demanding operating environments. Additionally, the maximum temperature of the friction surface during braking increased with the initial speed, reaching approximately 728.5 °C at an initial speed of 400 km/h, suggesting that this brake disc can adapt to the higher speeds of high-speed trains. However, repeated thermal stress cycles led to the formation of thermal fatigue cracks at the bolt holes of the coating. The laser cladding coating preparation method used in this study is efficient and cost-effective, producing coatings with high braking performance. This method meets the operational requirements of higher-speed high-speed trains and can extend the service life of brake discs, significantly reducing economic costs by adopting a replace-before-repair approach. It also provides an engineering example for the preparation of coatings on other large parts.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142433075","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 of the failure mechanisms of Zr alloy with Cr2AlC coatings using in-situ bending tests: Experiments and simulations","authors":"Boyu Pan ,&nbsp;Fuhui Shen ,&nbsp;Matej Fekete ,&nbsp;Devi Janani Ramesh ,&nbsp;Jochen Schneider ,&nbsp;Sebastian Münstermann","doi":"10.1016/j.engfailanal.2024.108964","DOIUrl":"10.1016/j.engfailanal.2024.108964","url":null,"abstract":"<div><div>The failure mechanisms of Cr₂AlC-coated zirconium samples under different mechanical loading conditions have been investigated by combining in-situ bending tests and finite element simulations. The results of interrupted in-situ bending tests reveal that new critical cracks are mainly initiated in the Cr₂AlC coating layer, followed by subsequent propagation into the Zr substrate with increasing plastic deformation. The formation of new critical cracks in Cr₂AlC material is described using the maximum principal stress criterion. A stress state-dependent damage mechanics model combined with an advanced plasticity model is used to capture the ductile fracture behavior of the Zr substrate. Finite element simulations have been performed to identify the failure properties of coating and substrate materials, leading to the accurate reproduction of experimental fracture behavior.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142537332","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":"Ground failure and soil erosion caused by bursting of buried water pipeline: experimental and numerical investigations","authors":"Hui Chao ,&nbsp;Yong Tan ,&nbsp;Ze-Kun Su","doi":"10.1016/j.engfailanal.2024.108965","DOIUrl":"10.1016/j.engfailanal.2024.108965","url":null,"abstract":"<div><div>Pressurized water pipelines buried in an urban environment are prone to bursting failures, threatening public safety and traffic convenience. The limited studies in literature just focused on soil fluidization while few studies considered ground failure, shear strain, soil erosion and the influence of leakage locations during pipe bursts. In this study, extensive experimental tests along with a finite difference method – discrete element method (FDM-DEM) solid–fluid coupling analysis were conducted to investigate these issues. It was disclosed that the failure development during pipe bursts can be divided into three stages, i.e., seepage diffusion, erosion cavity expansion, and soil fluidization. By digital image correlation (DIC) analysis of the experimental results, a wedge-shaped displacement zone in ground was identified, with peak shear strain near its boundaries. Moreover, it was revealed that leakage locations affected the expansion origin of erosion cavity; as the burial depths increased, the ground heave range increased linearly; the maximum water outflow distance was closely related to the internal pressures of buried pipeline, which could be modeled by a square root formula based on turbulent jet theory. Mesoscopic analyses revealed that finer particles were more susceptible to erosion during pipe bursts because of the low possibility of forming strong connections with surrounding particles. The findings yielded from this study can enhance the understanding of pipe bursts and help professionals mitigate potential damage.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142437772","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 tooth surface pitting on dynamic characteristics under mixed lubrication","authors":"Jiang Zhao ,&nbsp;Chenbo Ma ,&nbsp;Yuyan Zhang ,&nbsp;Zhengminqing Li ,&nbsp;Xiaofeng Yu ,&nbsp;Wei Sheng","doi":"10.1016/j.engfailanal.2024.108961","DOIUrl":"10.1016/j.engfailanal.2024.108961","url":null,"abstract":"<div><div>The variation of tooth meshing stiffness and frictional characteristics caused by tooth surface pitting increases vibration and noise in the gear transmission system. Assuming a smooth tooth surface and a homogeneous material in studying the gear contact and dynamics is insufficient to reveal the evolution of dynamic contact performance caused by pitting faults. In the present study, we established a coupling analysis model for pitting faults to assess the effect of the tooth surface micro-morphology. The mesh stiffness and static transmission error of gears with randomly distributed pittings were calculated, and the vibration response of gears with different pitting degrees was resolved. Finally, the effectiveness of the applied dynamic response theory analysis was experimentally verified using the constructed pitting fault simulation test bench. The results indicate that pitting failure decreases the effective load-bearing capacity of gear teeth. The mesh stiffness gradually but significantly decreased with the pitting degree, also exhibiting fluctuating values. Pitting faults induced significant periodic features in the vibration response of gear transmission systems, showing complex sidebands around the meshing frequency and its harmonics.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142437773","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":"Enhanced fatigue SN curve generation for gear bending fatigue life prediction using multi-objective optimization algorithms","authors":"Kibok Lee,&nbsp;Jiyoon Oh,&nbsp;Myeongeui Song","doi":"10.1016/j.engfailanal.2024.108960","DOIUrl":"10.1016/j.engfailanal.2024.108960","url":null,"abstract":"<div><div>This study presents a comprehensive methodology for fatigue life prediction and SN curve generation in gear systems, integrating specimen and product-level testing, simulations, and multi-objective optimization. The approach addresses the discrepancy between specimen-based testing and actual product performance through a novel multi-fidelity framework. To solve the proposed multi-objective optimization problem, several optimization algorithms were compared and analyzed, demonstrating the effectiveness of each approach in balancing different objectives. A key innovation is the development of an empirical formulation-based surrogate model, enabling efficient optimization while significantly reducing computational demands. The methodology covers both specimen and product-level testing along with simulations, offering a holistic solution for accurate fatigue life prediction. Extensive validation through experiments and comparison with commercial software confirms the reliability and practical applicability of the proposed method. This approach provides a sustainable and efficient solution for SN curve generation and fatigue life prediction in automotive gear train development, allowing for continuous improvement as new data becomes available. Its practicality and accuracy make it particularly valuable for early-stage design optimization and large-scale applications not only in the automotive industry but also in many other industries where gear fatigue analysis is critical.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142537438","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":"Impact force-damage depth model for ship-bridge collision","authors":"Liu X,&nbsp;Wu H,&nbsp;Chen D","doi":"10.1016/j.engfailanal.2024.108963","DOIUrl":"10.1016/j.engfailanal.2024.108963","url":null,"abstract":"<div><div>The impact force-damage depth model, i.e., <em>P</em>-<em>a</em> model, provides a feasible approach to design and evaluate bridge resistance under ship collisions, which is inadequately addressed in the existing specifications and literature. In the present study, based on an 18500 DWT (deadweight tonnage) bulbous bow bulk carrier and the main tower of cable-stayed bridges, the <em>P</em>-<em>a</em> model for ship-bridge collision is established with consideration of pile cap, bridge pylon and striking ship. Firstly, the refined finite element (FE) model of prototype ship was established with detailed modeling of both the main and stiffening components. The material model parameters and FE analysis approach were validated through the existing tensile tests on marine steel coupons and crush tests on ship bow specimens. It is found that the modeling of stiffening components has rationality in predicting the impact force and asymmetrical folding collapse of ship bow. Then, concerning two collision scenarios with the main tower of cable-stayed bridges, i.e., only bulbous bow-pile cap collision and sequential bulbous bow-pile cap and bow overhang-bridge pylon collisions, the influences of nine critical parameters from pile cap (height, curvature and water level), bridge pylon (width, curvature, angle and bow overhang-bridge pylon distance) and striking ship (mass and velocity) on the impact forces and failure patterns of ship bow were comprehensively discussed. It indicates that: (i) the larger impact forces of bulbous bow and bow overhang appear with increased pile cap height, decreased bridge pylon curvature and inward inclined pylon angle; (ii) the loading paths of <em>P</em>-<em>a</em> relationships are approximately identical with different striking ship masses and velocities. Finally, the <em>P</em>-<em>a</em> model for ship-bridge collision was established by response surface methodology, and the corresponding calculation procedure was further given and validated.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142444624","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":"A novel wheel wear indicator in regard to wheel-rail contact parameters and vehicle hunting stability","authors":"Hongxing Gao ,&nbsp;Jianfeng Sun ,&nbsp;Xiaohao Chen ,&nbsp;Weidong Jiao ,&nbsp;Maoru Chi ,&nbsp;Yonghua Jiang ,&nbsp;Wanxiu Xu ,&nbsp;Xuesong Jin","doi":"10.1016/j.engfailanal.2024.108967","DOIUrl":"10.1016/j.engfailanal.2024.108967","url":null,"abstract":"<div><div>It is well known that the abnormal equivalent conicity caused by wheel and rail wear is the main root of hunting instability, but it is still difficult to trace the underlying factor when the dynamic instability occurs, that is, wheel wear induced, rail wear induced or both. To face this challenge problem, this paper constructed a novel wheel wear indicator based on the moved wear area difference. The long-term tracking test data of different wheel profiles were used to analyze the correlation between the wear indicators and the wheel-rail contact parameters. A fully detailed dynamic model of one typical high-speed railway vehicle was developed to investigate the evolution of vehicle hunting stability under the variation of the proposed wear indicator. The results indicate that the proposed wear indicator based on the moved wear area difference has a strong correlation with the equivalent conicity and can be used for the estimation of wheel-rail contact conditions. Furthermore, the hunting stability and the instability form is closely related to the value of the proposed wheel wear indicator, which is helpful to trace the underlying factor of hunting instability, thereby supporting intelligent operation and maintenance of railway vehicles.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142537432","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}