Engineering Failure Analysis最新文献

{"title":"Investigation of defect formation in cold pilgered stainless steel pipes: Role of grain size and secondary phases","authors":"Sagar Patil ,&nbsp;Vishal Shambu ,&nbsp;Sayeri Chatterjee ,&nbsp;Dhananjay Bajpeyee ,&nbsp;Nilesh Suryawanshi ,&nbsp;M.J.N.V. Prasad","doi":"10.1016/j.engfailanal.2025.109587","DOIUrl":"10.1016/j.engfailanal.2025.109587","url":null,"abstract":"<div><div>This study investigates the typical failures of austenitic stainless steel (ASS) pipes used in the petrochemical sector, with a focus on surface defects that emerge during the cold pilgering process. Defects formed during cold pilgering of pipes of four different stainless steel grades such as AISI 304L, AISI 321, AISI 316Ti, and AISI 316L were examined in detail. The defects were examined via stereo-microscopy and scanning electron microscopy (SEM) along the surface and cross-section to visualize the length scale of the defects. Microstructural examination was performed using optical microscope and SEM to correlate the role of grain size, inclusions, and other microstructural heterogeneity. Through failure analysis, it becomes evident that excessive and intensive fissure formation (metal folding) is the root cause of the defect formation. The study highlights the impact of parameters such as the <em>Q</em> factor, grain size, secondary phase and inclusions such as titanium nitride in cold pilgered pipes on fissure development. A comprehensive metallurgical analysis via optical and scanning electron microscopy of the ASS pipes containing defects is provided in this paper.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109587"},"PeriodicalIF":4.4,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143817723","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":"Role of weld nugget size at Al/steel and steel/steel interface in fatigue behavior of three-sheet Al-steel-steel dissimilar resistance spot welds","authors":"Liting Shi ,&nbsp;Blair E. Carlson ,&nbsp;Guanyou Li ,&nbsp;Hassan Ghassemi-Armaki","doi":"10.1016/j.engfailanal.2025.109589","DOIUrl":"10.1016/j.engfailanal.2025.109589","url":null,"abstract":"<div><div>Resistance Spot Welding (RSW) has been effectively applied to join aluminum alloys with steel. However, welding aluminum alloys to advanced high-strength steels (AHSS), which are widely used in automotive structures, remains a challenge. This study utilized a high-strength low-alloy (HSLA) or low-carbon steel (LCS) sheet as an intermediate layer between aluminum and AHSS to create three-layer Al-steel-steel RSWs. The resulting welds exhibited large nugget diameters in both aluminum and steel, along with the formation of a thin and uniform intermetallic compound (IMC) at the aluminum-steel interface. The joint strength and fatigue performance of the three-sheet aluminum-to-steel welds were comparable to those of two-sheet welds. However, the fatigue life data did not converge to a single master curve using structural stress analysis, indicating that the diameter of the aluminum weld nugget is not the only factor influencing fatigue performance. Conversely, the steel weld nugget size significantly affected joint stiffness and fatigue life. By adopting the maximum principal strain approach, all fatigue data collapsed onto one master curve, suggesting it as a more reliable parameter for predicting fatigue life in three-sheet RSW configurations.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109589"},"PeriodicalIF":4.4,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800022","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":"Predicting the fracture initiation of dual-phase steels under different stress paths through an implicit stress update scheme","authors":"Toros Arda Akşen ,&nbsp;Neslihan Özsoy ,&nbsp;Emre Esener ,&nbsp;Murat Özsoy ,&nbsp;Mehmet Fırat","doi":"10.1016/j.engfailanal.2025.109578","DOIUrl":"10.1016/j.engfailanal.2025.109578","url":null,"abstract":"<div><div>Dual-phase steels are extensively utilized materials in automotive parts to reduce the weight of the autobody and increase fuel performance. Since most of the parts in the autobody are subjected to different loading conditions, the fracture initiation limits of these steels have become significant in recent years. This study systematically investigates the effects of anisotropic plasticity modeling on the ductile fracture predictions and forming limit curves (FFLCs) of dual-phase steels (DP600 and DP800), commonly utilized in automotive applications. Experimental uniaxial tensile tests were performed in multiple material orientations to characterize anisotropic mechanical responses, and these data were used to calibrate the sixth-order polynomial-based anisotropic yield criterion (HomPol6). Additionally, tensile tests on four notched geometries were conducted to provide stress state-dependent fracture strains, facilitating calibration of the DF2016 ductile fracture model. Notably, the calibration procedures were separately conducted for isotropic (von Mises) and anisotropic (HomPol6) yield criteria to critically evaluate their effects on fracture prediction accuracy. A detailed theoretical discussion is provided regarding the discrepancies observed in equivalent plastic strain, stress triaxiality, and Lode parameters between isotropic and anisotropic constitutive models, highlighting the intrinsic dependence of stress state evolution on anisotropic plastic flow. Subsequently, Finite Element (FE) analyses of the Nakajima tests were implemented using an implicit Marc solver with user-defined material subroutines (Hypela2). The numerical FFLC predictions obtained using the anisotropic calibration demonstrated enhanced agreement with experimentally derived literature data compared to the isotropic approach, explicitly highlighting the importance of anisotropic constitutive modeling. Furthermore, this study elucidates how critical numerical factors, such as friction, contact mechanics, mesh discretization, and bending effects in the Nakajima tests, interact with anisotropy to influence FFLC predictions. Finally, clear recommendations are provided for future experimental and theoretical directions, emphasizing the necessity of developing fully anisotropic fracture criteria to comprehensively capture orientation-dependent fracture ductility in advanced high-strength steels.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109578"},"PeriodicalIF":4.4,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143799898","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 technological research on grouting and curing of surface moraine collapse pits in block caving mining","authors":"Minggui Jiang ,&nbsp;Wei Sun ,&nbsp;Shaoyong Wang ,&nbsp;Xinglong Feng ,&nbsp;Zhengrong Li ,&nbsp;Haiyong Chen ,&nbsp;Chong Chen","doi":"10.1016/j.engfailanal.2025.109574","DOIUrl":"10.1016/j.engfailanal.2025.109574","url":null,"abstract":"<div><div>Collapse pits are highly susceptible to secondary hazards such as underground debris flows and slope instability under mining disturbances. These hazards significantly damage the ecological environment of the mining area. To reduce the geological hazards of collapse pits, grouting is used for management. The diffusion pattern and curing mode of slurry under different grouting pressures were investigated through indoor grouting simulation tests, and industrial tests were carried out to assess grouting effects. The results indicate that the slurry is dominated by penetration diffusion and supplemented by splitting diffusion in the moraine. The penetration distance and diffusion radius of the slurry increase linearly with grouting pressure, while the splitting uplift distance and cured volume increase exponentially with grouting pressure. Splitting diffusion consists of three stages: bulging compaction, splitting flow, and passive uplift. Horizontal splitting has a vertical uplift effect on the formation. The slurry primarily consolidates individual moraine particles into a cohesive mass by filling fractures, binding soil particles, and reinforcing interfaces with the rock mass. For different moraine layer structures, full-hole, segmented, and point-based grouting methods were applied. A composite grouting technique, “layered grouting with ring solidification,” was also introduced, achieving excellent grouting results. This study provides technical support for managing geological hazards in collapse pits caused by block caving mining disturbances and for green mining practices.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109574"},"PeriodicalIF":4.4,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143792242","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":"Damage identification in reinforced concrete beams using damage index derived from stiffness reduction","authors":"Akshat Dimri,&nbsp;Sushanta Chakraborty","doi":"10.1016/j.engfailanal.2025.109575","DOIUrl":"10.1016/j.engfailanal.2025.109575","url":null,"abstract":"<div><div>Reinforced concrete structures are widely used in civil construction and need regular monitoring during their comparatively long service period. Timely detection of damages is one of the most important strategies for successful health monitoring. Experimental modal testing and subsequent analysis is a popular vibration-based technique to determine structural damage in a non-destructive manner. In the present investigation, experimental modal testing was carried out over six reinforced concrete beams to understand the correlation between the changes in dynamic responses and structural damages at the onset of concrete cracking, as well as during the yielding of reinforcing bars and finally, at the ultimate load. Damages were inflicted on the reinforced concrete beams quasi-statically using a universal testing machine and modal testing was conducted in between each loading and unloading cycle. The results obtained were used to update a representative finite element model of the tested beams at each stage of damage to assess the equivalent stiffness loss. A damage index based on the percentage variation of the stiffness properties of the beam along the length has been used. Investigations were conducted on six reinforced concrete beams, three having a length of 1.8 m and the remaining three slightly longer- 3.3 m, and the damage indices thus identified were found to be effective in locating and quantifying both damaged and impending damage regions in terms of loss of stiffness.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109575"},"PeriodicalIF":4.4,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800023","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":"Estimation of remaining fatigue life of railway bogie substructures considering the degradation of axle box vibration: A case study for sanding device","authors":"Ningrui Yang ,&nbsp;Xingwen Wu ,&nbsp;Zhenxian Zhang ,&nbsp;Bo Zhang ,&nbsp;Bo Peng ,&nbsp;Yang Liu ,&nbsp;Junzuo Liu ,&nbsp;Wubin Cai ,&nbsp;Maoru Chi ,&nbsp;Shulin Liang","doi":"10.1016/j.engfailanal.2025.109580","DOIUrl":"10.1016/j.engfailanal.2025.109580","url":null,"abstract":"<div><div>The bogie system, a critical component of railway vehicles, endures complex cyclic loads from wheel-rail interactions, vehicle motion, and traction-braking forces. Progressive wheel out-of-roundness (OOR) amplifies dynamic loads, induces high-frequency resonance, and accelerates fatigue damage in bogie sub-components such as the sanding device. This study proposes a fatigue life prediction framework that integrates axle box vibration spectrum degradation and wheel-rail coupled vibration into frequency-domain damage estimation. The vibration spectrum evolution is modeled and predicted using a nonlinear Wiener process, capturing the stochastic nature of spectral degradation. The framework combines rigid-flexible coupled simulations, field vibration tests, and frequency-domain fatigue algorithms to quantify the impact of spectral shifts on damage accumulation. The results show that considering both spectral evolution and wheel-rail coupled vibration leads to the predicted earlier failure, with the sanding device’s remaining useful life (RUL) reduced by up to 75 % under severe OOR conditions. This method enables real-time fatigue prediction and iterative recalibration, supporting condition-based maintenance and fatigue-resistant design, ultimately enhancing the reliability and economic efficiency of railway vehicle operations.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109580"},"PeriodicalIF":4.4,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143792213","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 laser directed energy deposited high-strength alloys on the bainitic crossing noses in a rolling-sliding contact","authors":"Beibei Zhu,&nbsp;Li Meng,&nbsp;Gaofeng Xu,&nbsp;Xu Liu,&nbsp;Qianwu Hu,&nbsp;Xiaoyan Zeng","doi":"10.1016/j.engfailanal.2025.109579","DOIUrl":"10.1016/j.engfailanal.2025.109579","url":null,"abstract":"<div><div>The 17-4PH, 420SS, and 18Ni300 deposits were prepared to repair the bainitic crossing nose via laser directed energy deposition (L-DED) technology, and their mechanical properties, wear and rolling contact fatigue (RCF) damage behaviors and microstructure evolution were analyzed. The findings indicate that 420SS and 18Ni300 deposits exhibit higher yield strength compared to the bainitic crossing nose, and 18Ni300 and 17-4PH deposits demonstrate better impact work. The wear mechanism of bainitic crossing nose is fatigue wear, which changes to adhesive wear after preparing high-performance deposits by L-DED. The microstructure evolution law within the deposits is as follows: dislocation accumulation gives rise to the formation of low-angle grain boundaries. Subsequent strain accumulation transforms austenite into martensite within the multiphase structure, leading to the development of subgranular boundaries that evolve into high-angle grain boundaries and eventually nanocrystalline grains. Among the three martensitic steel deposits examined, the 18Ni300 deposit stands out for its good wear and RCF resistance. This superiority is attributed to several factors: the retained austenite hinders RCF crack propagation via the transformation-induced plasticity effect, and numerous nano-precipitates enhance the shakedown limit. Under rolling-sliding contact, the austenite fully transforms into martensite consistent with the parent phase, without micro-regional stress concentrations. These findings can lay a theoretical foundation for regulating the microstructure and performance of deposits, ultimately preventing wear and RCF failures at railway crossings.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109579"},"PeriodicalIF":4.4,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Tensile performance of carbon fibre-reinforced 3D-printed polymers: Effect of printing parameters","authors":"Clare Burnett ,&nbsp;Georg Graninger ,&nbsp;Zana Eren ,&nbsp;Brian G. Falzon ,&nbsp;Zafer Kazancı","doi":"10.1016/j.engfailanal.2025.109577","DOIUrl":"10.1016/j.engfailanal.2025.109577","url":null,"abstract":"<div><div>The mechanical performance of fibre-reinforced 3D-printed composites is highly dependent on slicing and processing parameters, yet a systematic understanding of these effects remains limited. This study aims to systematically evaluate the influence of infill pattern, infill density, bed orientation, and layer thickness on the tensile properties of short carbon fibre-reinforced Nylon (Onyx) and unreinforced Nylon fabricated using Markforged 3D printers. Tensile testing was conducted to assess tensile modulus, ultimate tensile strength, elongation at break, and Poisson’s ratio across varying slicing parameters. Various raster angles (0°, 90°, 45° and −45° relative to the x-axis), three infill patterns (rectangular, triangular, hexagonal), and multiple densities (17 %–92 %) were examined to assess their influence on mechanical behaviour. Scanning electron microscopy (SEM) and fibre volume fraction ignition testing were used to quantify void content and fibre distribution in Onyx composites. Furthermore, the Rule of Mixtures (ROM) was applied and demonstrated strong agreement with experimental results, providing a predictive framework for tensile performance across different infill densities. The findings of this study contribute to the optimisation of fibre-reinforced additive manufacturing by identifying key parameters that enhance mechanical properties, supporting structural applications in aerospace, automotive, and lightweight engineering systems.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109577"},"PeriodicalIF":4.4,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785533","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 modes and damage superposition effect of concrete gravity dams subjected to sequential underwater explosions","authors":"Yumeng Lei ,&nbsp;Jing Hu ,&nbsp;Zuyu Chen ,&nbsp;Mingsheng Cao ,&nbsp;Xuedong Zhang ,&nbsp;Ruozhan Wang ,&nbsp;Yu Zhao ,&nbsp;Hongchen Liu","doi":"10.1016/j.engfailanal.2025.109576","DOIUrl":"10.1016/j.engfailanal.2025.109576","url":null,"abstract":"<div><div>Underwater explosion damage and failure modes in concrete gravity dams are crucial for understanding the blast resistance and protective capabilities of dam structures. With the increasing severity of international security and anti-terrorism concerns, the related research has received widespread attention. Existing research primarily focuses on single explosion. However, concrete gravity dams may suffer multiple attacks before its breaching. The damage and failure modes of dams under multiple explosions remain unclear. To analyze the failure mechanisms of the dams subjected to sequential underwater explosions, and enhance the blast resistance and protective capabilities of dams, this research establishes a fully coupled numerical model to determine the dynamic response process and failure mechanism of concrete gravity dams under double detonations conditions. The centrifuge tests of underwater explosions with double detonators on concrete gravity dams were conducted to validate the numerical simulation results. On this basis, the damage characteristics and failure modes of gravity dams under different delay intervals, initiation sequences, and equivalent combinations were investigated. The results indicate that underwater explosions of concrete gravity dam exhibit damage superposition effect under the condition of double detonations. There is a worst delay interval such that when the explosion equivalent is consistent, the damage of concrete dam is larger and the destruction is more pronounced. The worst delay interval is determined by the duration of dam dynamic response process, and is influenced by the combination of explosion equivalent and initiation sequence. This research can provide valuable insights for the dam safety protection.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109576"},"PeriodicalIF":4.4,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143799906","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 TiNbCr Multi-Principal element Alloy: Temperature-Dependent oxidation and internal degradation in oxygen atmospheres","authors":"Isabela Dainezi ,&nbsp;Brian Gleeson ,&nbsp;Carlos Alberto Della Rovere","doi":"10.1016/j.engfailanal.2025.109573","DOIUrl":"10.1016/j.engfailanal.2025.109573","url":null,"abstract":"<div><div>This study presents a failure analysis of a TiNbCr multi-principal element (MPE) alloy, focusing on its temperature-dependent oxidation behavior and internal degradation mechanisms in oxygen atmospheres. Thermal gravimetric analysis (TGA) conducted at varying temperatures revealed distinct oxidation mechanism: at 700 °C, a dense oxide layer formed; at 800 °C, a complex mixture of Nb, Ti, and Cr oxides was observed; and at 900 and 1000 °C, an innermost Cr₂O₃-rich layer developed, imparting improved oxidation resistance. Despite these temperature-dependent variations, the scaling kinetics of the alloy remained linear, with extensive internal oxidation observed at all exposure temperatures. In contrast, alloy 188 exhibited parabolic scaling kinetics and lower mass gain per unit area, demonstrating better oxidation resistance. The persistent presence of an internal reaction zone (IRZ) suggests that the oxide scale fails to act as an effective diffusion barrier, promoting internal degradation and increasing the risk of structural failure in high-temperature applications. Moreover, a comparison with previous studies suggests that the presence of nitrogen accelerates oxidation kinetics while reducing IRZ depth, affecting long-term material stability. These findings provide critical insights into oxidation-induced failure mechanisms, aiding in the development and selection of high-temperature alloys for aerospace, energy, and structural applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109573"},"PeriodicalIF":4.4,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777270","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}