Engineering Failure Analysis最新文献

{"title":"Effects of shot peening intensity and coverage on the fatigue life and fracture characteristics of DZ125 alloy at room and high temperatures","authors":"Kang Wu ,&nbsp;Kui Li ,&nbsp;Longlong Hao ,&nbsp;Jinglong Tang ,&nbsp;Xiangming Jin ,&nbsp;Jie Yang","doi":"10.1016/j.engfailanal.2024.108955","DOIUrl":"10.1016/j.engfailanal.2024.108955","url":null,"abstract":"<div><div>Nickel-based superalloys are widely used in aerospace and other fields, with their fatigue life being one of the crucial factors affecting their reliability and performance. To extend the fatigue life of the DZ125 alloy, the high-temperature (760 °C) and room-temperature (25 °C) fatigue properties under different shot peening (SP) parameters were studied. For circumferential V-notch (kt = 2.5) samples of the DZ125 alloy, SP was conducted using S110 shots with Almen intensities of 0.21mmA and 0.17mmA and coverage rates of 100 %, 200 %, and 300 %. The fatigue life is evaluated using an SP simulation method based on finite element and discrete element method (FEM-DEM) coupling, combined with surface residual stress and roughness testing. The results showed that when the sample coverage rate increased from 200 % to 300 %, the surface residual compressive stress has little difference, and the roughness increased from 2.1 μm to 2.63 μm, consistent with simulation results. SP can improve the fatigue life of DZ125 alloy. When the Almen intensity and coverage of 0.17mmA and 200 % respectively, the fatigue performance is the best. At high temperatures, the fatigue life of specimens with 300 % coverage is 1/6 that of those with 200 % coverage, while in a normal temperature environment, the fatigue life of specimens with 300 % coverage is not significantly lower than those with 200 % coverage. This indicates that when SP coverage is excessive, there surface defects causing surface stress relaxation. Under the influence of high temperatures, there is an oxidation damage process at the crack tip that promotes crack initiation and propagation, reducing fatigue life. The research results provide improved methods and experimental basis for enhancing the fatigue life of the DZ125 alloy.</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":"142433208","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":"Bond-slip model of corroded plain round bars in low-strength concrete under cyclic and monotonic loading","authors":"Özgür Yurdakul ,&nbsp;Eren Balaban ,&nbsp;Salih Serkan Artagan ,&nbsp;Ladislav Routil","doi":"10.1016/j.engfailanal.2024.108966","DOIUrl":"10.1016/j.engfailanal.2024.108966","url":null,"abstract":"<div><div>The effect of corrosion on the overall behavior of beam-type bond-slip samples constructed from low-strength concrete and plain round bars was examined in this study. First, a set of nominally identical specimens underwent testing under both monotonic and cyclic loading, and subsequently, the bond-slip interaction was assessed for each individual sample. The observed failure mode for plain round bars was direct pullout without concrete splitting apart, characterized by the loss of cohesion between the rebar and the adjacent concrete surface. Then, an analytical relationship was established by fitting a curve to the average experimental data using the method of least squares. Corrosion-degradation in the bond stress was considered by incorporating an exponential component into the equation of the reference bond-slip curve (i.e., null corrosion). Besides, the degradation in bond strength was predicted as a function of corrosion level, which is in the form of an exponential curve. The maximum surface crack width, an easily quantified variable on-site, was correlated with the bond strength of corroded bars. The regression analysis successfully established the optimal relationship between the maximum surface crack width and the corrosion level in an exponential form as well. Notably, the majority of the data in all cases fell within the 95% confidence interval.</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":"142444625","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":"Hygrothermal aging and durability prediction of 3D-printed hybrid fiber composites with continuous carbon/Kevlar-fiber and short carbon-fiber","authors":"Kaijin Guo ,&nbsp;Yiru Ren ,&nbsp;Guangchao Han ,&nbsp;Tiancai Xie ,&nbsp;Hongyong Jiang","doi":"10.1016/j.engfailanal.2024.108958","DOIUrl":"10.1016/j.engfailanal.2024.108958","url":null,"abstract":"<div><div>Hybrid Fiber Reinforced Polymers (HFRP) have excellent mechanical properties. However, preparation with 3D-printing technology is prone to hydrothermal aging compared to conventional method. Currently, complex hygrothermal aging and degradation mechanisms of 3D-printed HFRP are still unclear. Thus, hygrothermal aging and durability prediction of 3D-printed HFRP with continuous carbon/Kevlar-fiber and short carbon-fiber are studied, which considers four typical stacking sequences. All experimental samples are manufactured by Fused Deposition Modeling (FDM) 3D-printing. The artificial accelerate aging testing is conducted on samples at different times, and then flexural testing is adopted to evaluate the residual mechanical properties and failure modes. The results show that the stacking sequence significantly influences the moisture absorption behaviors, and [OC₄O₂K₄]_S absorbed more moisture than [OK₄O₂C₄]_S. During the aging process, the flexural properties of the 3D-printed HFRP first decrease rapidly and then keep stable. Among them, [OK₄O₂C₄]_S have the fastest degradation but possessed the highest residual strength. OC₈O₄K₈O possess the slowest degradation but have a lower residual strength. The morphologies and micro failure modes/mechanisms are analyzed to explain the significant mechanical degradation. Finally, the Arrhenius relationship is adopted to accurately predict and analyze the degradation evolution process of specimens. This work offers a novel perspective on the hygrothermal aging and durability of 3D-printed HFRP.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142433209","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":"Application of inverse heat transfer to fatigue fracture","authors":"Mohammad A. Amooie,&nbsp;Hunter B. Gilbert,&nbsp;Peyton J. Wilson,&nbsp;Michael M. Khonsari","doi":"10.1016/j.engfailanal.2024.108951","DOIUrl":"10.1016/j.engfailanal.2024.108951","url":null,"abstract":"<div><div>Cyclic actuation tends to cause self-heating in the material as the structure experiences fatigue, where the movement and coalescence of defects lead to crack formation, propagation, and eventual fracture. This study explores the modeling aspects of the self-heating phenomenon using a one-dimensional inverse heat problem to analyze heat generation and dissipation to quantify the plastic work rates needed for predicting fatigue life. The approach is based on analyzing the surface thermography obtained using an infrared camera and numerically solving an inverse Fourier heat conduction equation. Formulation of the inverse problem via constrained optimization and method of solution for analyzing the fatigue behavior of CS 1018 flat dog bone specimens subjected to fully reversed bending fatigue are presented. The proposed model demonstrates superior accuracy in predicting the location of maximum heat generation and identifying potential fracture zones compared to traditional methods.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417915","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 evolution and acoustic emission characteristics of sandstone under different true triaxial cyclic loading and unloading modes","authors":"Qihang Zhang ,&nbsp;Xiangrui Meng ,&nbsp;Guangming Zhao ,&nbsp;Yingming Li ,&nbsp;Wensong Xu ,&nbsp;Chongyan Liu ,&nbsp;Zhixi Liu ,&nbsp;Xukun Wu ,&nbsp;Zhihong Qin ,&nbsp;Kun Wang","doi":"10.1016/j.engfailanal.2024.108947","DOIUrl":"10.1016/j.engfailanal.2024.108947","url":null,"abstract":"<div><div>In the process of deep coal mining, the cyclic mining disturbance behavior produces significant cyclic loading and unloading effects, to ensure safe production in the mining area, it is necessary to study the damage characteristics and acoustic emission characteristics of the rock body under different cyclic loading and unloading effects. This study developed a TAWZ-5000/3000 rock true triaxial (disturbance) test system and used it to carry out true triaxial cyclic loading and unloading tests in different modes, with acoustic emission (AE) monitoring of the deformation and damage processes. The test results proved that a large number of cycles weakens the rock’s ability to control deformation, and this weakening ability is also related to the types of cyclic loading and unloading modes. The hysteresis loop characteristics and mechanical parameters show obvious path dependence. Based on the damage equivalence method, it is found that the absolute damage parameter increases with the increase of the number of cycles in the same mode, and the accumulation rate of the cumulative damage parameter is faster; the cumulative damage parameter in the equal amplitude cyclic loading and unloading (EAC) mode is always higher than that in the other two modes. The normalized AE ring count rate in the rock samples under cyclic loading and unloading has a significant relationship with the damage percentage, and the crack extension scale function (<em>b</em>-value) shows the “steady increase – strong fluctuation − significant decline” trend. By analyzing the AE characteristic parameters, namely rise time/amplitude (RA) and ringing count/duration (AF), it is found that the sandstones in EAC, graded cyclic loading and unloading (GC), and stepped cyclic loading and unloading (SC) modes are mainly damaged by tension-shear and shear, respectively. By analyzing the values of the acoustic emission parameters RA-AF, it is found that the sandstone is mainly damaged by tensile shear, tensile tension, and shear under EAC, GC, and SC modes, respectively, corresponding to the rock samples’ damage patterns. The study results have important guiding significance for preventing and controlling disasters in deep mines.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417920","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 reliability analysis methodology based on fatigue life and failure mechanism for carburized gear","authors":"Hailong Deng ,&nbsp;Jianhang Kong ,&nbsp;Jie Liu ,&nbsp;Zhiyu Hu ,&nbsp;Yufan Sun ,&nbsp;Yupeng Guo ,&nbsp;Liming Song ,&nbsp;Huan Yu","doi":"10.1016/j.engfailanal.2024.108950","DOIUrl":"10.1016/j.engfailanal.2024.108950","url":null,"abstract":"<div><div>Gears are one of the important components in mechanical products, and their fatigue reliability determines the safety performance of mechanical products. In this paper, the fatigue characteristics of carburized gears under different torque and constant rotational speed conditions are investigated by using a gear contact fatigue testing machine, and combined with the dynamic maximum contact stress distribution on the subsurface of the meshing gears, the very-high cycle fatigue <em>P</em>-<em>S</em>-<em>N</em> curves of carburized gears under a stress ratio of −1 is established. Local stress concentration in the surface or subsurface of carburized gears causes grain dislocation movement under the combined influence of maximum contact and residual stresses, and then causes dislocation pileup and transcrystalline rupture after being hindered by grain boundaries, ultimately leading to pitting and fatigue failure of gears. Based on the dislocation energy method and combined with the fatigue failure mechanism of gears, a life prediction model of gears with good prediction results is established by considering the interaction of factors such as dynamic load, grain size, initial crack length, residual stress, slip band length and width. A fatigue reliability analysis method of gears is established based on the life state equation of gears considering the life prediction model. Further analyses of the influence of rotational speed, grain size, residual stress, slip band width, slip band length and initial crack size on the fatigue life reliability index of the gears resulted in the conclusion that the fatigue reliability of the gears not only decreases with the increase of the above-mentioned parameters, but also shows decreasing trend with the increase of time. This is of significance for evaluating the fatigue reliability of gears under very-high cycle fatigue conditions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417914","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":"Prestressed concrete slabs subjected to low-velocity impact: Theoretical analysis model and design method","authors":"Zeyi Wang ,&nbsp;Quanquan Guo","doi":"10.1016/j.engfailanal.2024.108949","DOIUrl":"10.1016/j.engfailanal.2024.108949","url":null,"abstract":"<div><div>Bidirectional bonded prestressed concrete (PS) structures are widely used in energy engineering structures due to their excellent impermeability. Owing to the particularity of the structure and the severity of damage consequences, the impact dynamic performance of bidirectional bonded PS structures has been widely concerned. Nonetheless, the existing researches focus on the test and finite element, and lacks the theoretical analysis model that can consider the whole process of load action, let alone the corresponding anti-impact design method. Therefore, based on the existing test and finite element results, the resistance function model of bidirectional bonded PS slab is proposed in this paper, and the anti-impact design method is formed. Firstly, the performance of specimens under low-velocity impact loading and quasi-static loading conditions is compared, and the effects of inertia force and material strain rate on the dynamic performance of specimens under low-velocity impact are further explored. Then, a resistance function theoretical analysis model that can consider the whole process of load action is proposed with a quadrilinear form, and the analytical expressions of resistance and stiffness at characteristic points are derived. Subsequently, the accuracy of the resistance function model is verified based on the existing test results. Furthermore, based on the resistance function model, the influence laws of compressive strength of concrete, prestressing degree, reinforcement ratio of reinforcement and slab thickness on slab resistance are analyzed. Finally, an anti-impact design method considering perforation and scabbing failure is proposed, and the feasibility of the design method is verified by impact test results.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142433210","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 assessment of seam-welded pipe under fatigue and thermal loading","authors":"Mohamed Gadala ,&nbsp;Ibrahim Gadala ,&nbsp;Abdulrahman Gomaa","doi":"10.1016/j.engfailanal.2024.108934","DOIUrl":"10.1016/j.engfailanal.2024.108934","url":null,"abstract":"<div><div>This paper presents an assessment of the failure of a seam-welded pipeline under fatigue and thermal loading. The investigation concentrated on analyzing several factors potentially influencing pipeline failure. Both experimental analysis and numerical simulations utilizing the finite element method (FEM) were conducted to understand potential failure modes of a seam-welded SS304L pipeline. The experimental and FEA analyses investigated various failure factors including weld defects, fatigue and thermal loading, residual stresses, and overloads. The study concludes that substandard welding procedures and inadequate post-weld treatment, coupled with elevated residual stresses in the heat-affected zone (HAZ) of the weld, were the primary contributors to failure. The paper systematically outlines the utilization of experimental and FE analyses in examining practical engineering failure instances. This approach strengthens the ability to avert failures and navigate risks with precision. Furthermore, the results highlight the critical significance of adhering to code and standard guidelines concerning pipe seam welds and post-weld treatment practices.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142433235","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":"Failure mechanism and crashworthiness optimization of variable stiffness nested origami crash box","authors":"Shaohua Xing ,&nbsp;Zhiyu Jiang ,&nbsp;Jian Zhao ,&nbsp;Xudong Sun ,&nbsp;Yan Wang","doi":"10.1016/j.engfailanal.2024.108953","DOIUrl":"10.1016/j.engfailanal.2024.108953","url":null,"abstract":"<div><div>In recent years, the study of the crashworthiness of lightweight and efficient thin-walled energy-absorbing structures has received increasing attention. In this work, 3D printing technology was adopted to create a nested origami crash box with stiffness variation, which was made of short carbon fiber reinforced nylon material. The structure effectively inhibits the development of failure behavior of short carbon fiber-reinforced nylon origami crash box due to material brittleness. The quasi-static compression experiment results indicate that compared to origami crash box, nested origami crash box improves by 40% in specific energy absorption and 50% in crash force efficiency, while the initial peak crushing force remains unchanged. The effects of three key geometrical parameters, namely dihedral angle, distance between tubes, and height difference on the damage mechanism of the nested origami crash box are discussed in detail using the finite element method, and the response surface model combined with the non-dominated sorting genetic algorithm II is used for multi-objective optimization. In this work, the concepts of origami theory and nested systems are integrated for the first time, aiming to achieve a stable and efficient energy-absorbing deformation mode by precisely modulating the stress transfer path of the structure and its stiffness. This work provides new ideas for the design and fabrication of novel lightweight energy-absorption boxes.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417924","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":"Analysis of fuel storage tanks under internal deflagrations with different venting technologies: an experimental and numerical study","authors":"Francisco Hernandez ,&nbsp;Luis Carcamo ,&nbsp;Hong Hao ,&nbsp;Xihong Zhang ,&nbsp;Nicolas Contreras ,&nbsp;Rodrigo Astroza","doi":"10.1016/j.engfailanal.2024.108948","DOIUrl":"10.1016/j.engfailanal.2024.108948","url":null,"abstract":"<div><div>This study investigates small-scale fuel storage tanks subjected to internal methane-air explosions, focusing on three depressurization technologies using roof ventilation to mitigate overpressure and damage. Tests with low methane-air concentrations were conducted to generate a pseudo-static internal pressure. This approach minimized scale effects and aligned internal pressure frequency with real-scale tank behavior during deflagrations. The first prototype features a tank with a frangible roof activated by localized brittle failure of stitch welds around the roof-to-shell junction. This confirms that stitched weld patterns ensure controlled brittle failure with activation pressure estimated by a simplified equation. The second technology employs a sequential ventilation strategy, starting with a small hinged panel followed by stitch weld failure, managing low to medium-intensity explosions with the small vent alone, and allowing rapid operational recovery. In severe explosions, the hinged door facilitates earlier activation of the frangible roof, reducing the initial pressure rise rate and controlling the roof opening direction. Lastly, the study explores tanks with commercial explosion vent panels as an alternative to traditional frangible roofs, offering a practical solution for retrofitting existing tanks. Each technology enhances safety in fuel storage facilities by effectively managing internal pressures during explosive events.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142537331","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}