Engineering Failure Analysis最新文献

{"title":"Mesoscopic coupled plasticity-damage model of rough surface considering size-dependent plasticity","authors":"Bin Li ,&nbsp;Bohong Zhang ,&nbsp;Yi Cui ,&nbsp;Lining Gao ,&nbsp;Shuo Liu ,&nbsp;Feng Zhu","doi":"10.1016/j.engfailanal.2024.108946","DOIUrl":"10.1016/j.engfailanal.2024.108946","url":null,"abstract":"<div><div>Metallic materials exhibit significant size effect at mesoscopic scale have been revealed by many experiments. Thus, it is essential to consider size effect when conducting mesoscopic scale studies in tribology. However, there is no constitutive model considering both ductile fracture and size effects of rough surface in the literature. At the same time, the simulation of friction and wear at the mesoscopic scale suffer from computational inefficiency using the conventional theory of mechanism-based strain gradient (CMSG) plasticity theory. To address the aforementioned challenges, we propose a mesoscopic coupled plasticity-damage model by combining the coupled plasticity-damage model and the simplified CMSG plasticity theory. This model can take into account not only the effect of stress state, temperature, strain rate on plasticity and fracture, but also the effect of the effective plastic strain gradient. Meanwhile, the model is able to solve the effective plastic strain gradient by a simplified method, thereby enhancing the computational efficiency. Then, model parameters for bearing bushing material of an engine are calibrated. Finally, scratch simulation and scratch tests of bearing bushing material at the mesoscopic scale are conducted to validate the effectiveness of the mesoscopic constitutive model. The residual scratch depth and width, coefficient of friction at different normal loads are investigated by experiment and simulation, respectively. Results proved the effectiveness of mesoscopic coupled plasticity-damage model, which is applicable for investigating issues related to wear, friction, and contact.</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":"142417926","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":"Load-bearing behaviors of the composite gravity-type anchorage: Insights from physical model and numerical tests","authors":"Chengtang Wang ,&nbsp;Hongju Han ,&nbsp;Hao Wang ,&nbsp;Xiuli Zhang ,&nbsp;Xinhua Liu ,&nbsp;Xianlun Leng ,&nbsp;Weimin Qin ,&nbsp;Kun Fang","doi":"10.1016/j.engfailanal.2024.108959","DOIUrl":"10.1016/j.engfailanal.2024.108959","url":null,"abstract":"<div><div>Gravity-type anchorages (GTAs) have been extensively applied in large-span suspension bridges across the globe, but the load-bearing performance of composite GTA is not yet fully investigated. Here, the comprehensive load-bearing performance of GTA is investigated using a combination of physical modelling and numerical modelling methods, considering the impact of anchorage’s burial depth, notched sill, and pile. Six model tests are first conducted using a self-reversing force loading equipment, including flat bottom anchorage, notched sill anchorage, and notched sill anchorage with pile. Each type of anchorage is tested under two different burial depth conditions. The failure process, anchorage displacement, cable tension force, and the internal strain field of the foundation, were examined during the model tests. Additionally, through the numerical simulations, the evolution characteristics of contact stresses and load sharing ratio associated with various forms of anchorage are discussed. The results indicate that the anchorage’s burial depth and pile significantly impact on anchorage’s bearing capacity. The presence of the notched sill can change the distribution of contact stress between the anchorage and foundation, which can still resist the horizontal force until the foundation before the notched sill occurs shear failure. The failure process of the anchorage-foundation system was divided into four stages: stable bearing, sliding, sliding and overturning, and failure stage. The anchorage starts overturning with the applied load reaching to 3*<em>T_m</em>, except for the flat bottom anchorage of shallow burial depth condition. Under the same conditions, the greater the anchorage’s burial depth, the smaller the load shared by the friction between the anchorage bottom and foundation, the greater the load shared by the notched sill and foundation before the anchorage. In addition, the load shared by pile continuously increasing as the anchorage starts overturning. The findings from this study can provide a theoretical basis and valuable insights for the optimization design of GTA.</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":"142433211","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":"Surface engineering of silica to control creep failure resistance of natural rubber-based composites for potential application in the suspension of rolling stock","authors":"Fateme Chavoshian,&nbsp;Mohammad Alimardani","doi":"10.1016/j.engfailanal.2024.108952","DOIUrl":"10.1016/j.engfailanal.2024.108952","url":null,"abstract":"<div><div>Immobilization of polymer chains by silica on one side could increase the viscoelastic energy loss and on the other could postpone chain relaxations and temporarily conceal creep deformation. It is not yet clear how the formation of an interphase layer contributes to the change of creep resistance. Bifunctional silane, “Bis(triethoxysilylpropyl) disulfide” is employed to induce various degrees of covalent bonds at the rubber-silica interface, and also brings multiple degrees of immobilization. Interestingly, it was found that by controlling interfacial phenomena, the creep rate can be altered in a wide range of 4.35–1.65 (%/decade). It was mechanistically explained how the maximum creep resistance is observed for the sample having a medium level of surface treatment. The formation of a filler network indicated an essential role in increasing the high-temperature creep failure of systems having no favorable polymer-filler interaction.</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":"142417921","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 gas–liquid–solid multiphase flow and erosion in ball valves","authors":"Desheng Chen ,&nbsp;Jingyu Jiang ,&nbsp;Lining Ming ,&nbsp;Guang Zhang ,&nbsp;Zhe Lin ,&nbsp;Hui Li","doi":"10.1016/j.engfailanal.2024.108945","DOIUrl":"10.1016/j.engfailanal.2024.108945","url":null,"abstract":"<div><div>In industrial processes involving ball valves, gas–liquid–solid multiphase flows with continuous carrier and discrete particle phases are characterised by erosion challenges. These challenges reduce sealing performance and can lead to leakage and valve failure. To explore the characteristics of gas–liquid–solid multiphase flow and flow-induced erosion in ball valves, we conducted a combination of computational fluid dynamics numerical simulations and experimental testing. Results indicate that an increase in the gas content increases the flow coefficient, accelerates both liquid flow and particle movement and exacerbates erosion. In addition, particles are less concentrated in regions with higher gas concentrations. Erosion is primarily observed on the upstream surface and rear wall of the valve core as well as the upper side of the downstream pipeline. Severe erosion occurs more at smaller valve openings, and affected regions expand as the valve opening increases.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417925","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 of oxide layer on performance and creep life of a superheater tube in a coal-fired power plant","authors":"Phanwadee Phomprasert ,&nbsp;Pornsak Thasanaraphan ,&nbsp;Nitikorn Noraphaipipaksa ,&nbsp;Chaosuan Kanchanomai","doi":"10.1016/j.engfailanal.2024.108941","DOIUrl":"10.1016/j.engfailanal.2024.108941","url":null,"abstract":"<div><div>The failure of a superheater tube in a coal-fired power plant, designed to resist creep damage at high temperatures and pressures, was investigated after it ruptured following 115,360 h of operation, which was significantly shorter than its expected 200,000-hour life. An oxide layer measuring 106 µm was discovered on the inner side of the tube, which acted as a thermal insulator, raising the tube’s temperature and reducing its thickness. This led to increased stress, decreased creep resistance, and a shortened tube life. The oxide layer’s growth, tube temperature, and stress were estimated. After 115,360 h, at a flue gas velocity of 22 m/s, the oxide layer reached an estimated thickness of 120 µm. The outer and inner tube surface temperatures were 522 °C and 510 °C, respectively, and the stress was estimated at 79.9 MPa. To extend tube life to the designed 200,000 h, it was determined that reducing the flue gas velocity to 15.8 m/s or lower would be required. At this velocity, the tube’s creep life was estimated at 200,070 h when accounting for tube thinning. Without accounting for the reduction in thickness, the estimated life was 210,650 h, which was approximately 1.2 years longer.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417912","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":"Seismic behavior and failure analysis of prefabricated foamed concrete composite walls for passive houses","authors":"Jiaheng Zhang ,&nbsp;Xiaomeng Ding ,&nbsp;Meloni Marco ,&nbsp;Zhongfan Chen","doi":"10.1016/j.engfailanal.2024.108937","DOIUrl":"10.1016/j.engfailanal.2024.108937","url":null,"abstract":"<div><div>In view of the lack of research on the failure mode and seismic behavior of high-performance insulation walls utilizing lightweight concrete as the structural material, this study presents experimental findings from a seismic behavior investigation of prefabricate foamed concrete composite walls (PFCCWs) for passive house in China. The PFCCWs incorporate low thermal conductivity and high-strength foamed concrete, polyurethane, decorative magnesium straw slabs to provide excellent thermal and mechanical properties for prefabricated passive houses in hot summer and cold winter area. The seismic behavior of PFCCWs under different influence factors were elaborated using quasi-static test data and observation of external damage. The lightweight and porous nature of foamed concrete leads to significant crack formation during failure. The findings suggest that the skin effect of magnesium straw slabs and polyurethane impedes crack development and improve the load-bearing capacity with ductility enhancement. Additionally, reducing the aspect ratio and substituting post-cast column concrete with common concrete are effective to improve the seismic behavior. The window opening changes the worst damage area of the wall and notably weakens the seismic behavior. The enhanced integrity of cast-in-place wall leads to the difference in the failure mechanism and increases in load-bearing and deformation capacities. Meanwhile, design suggestions for the foamed concrete insulation walls are also proposed by comparing the failure mode and hysteretic response of various wall types.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417720","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":"Unexpected dual cracks in chip-ceramic substrate interconnect: Unveiling the mechanism behind simultaneous cracking at both the top and bottom of a solder joint","authors":"Jinhong Liu ,&nbsp;Taotao Chen ,&nbsp;Qiangqiang Nie ,&nbsp;Junfu Liu ,&nbsp;Peng He ,&nbsp;Kyung-Wook Paik ,&nbsp;Shuye Zhang","doi":"10.1016/j.engfailanal.2024.108942","DOIUrl":"10.1016/j.engfailanal.2024.108942","url":null,"abstract":"<div><div>Chip-ceramic interconnect is increasingly vital in high-density IC especially in high-frequency applications, making the reliability of solder joints with underfill material in this case a significant concern. In this study, unexpected simultaneous cracking at both the top and bottom of a solder joint was noted after 500 thermal cycles. Crack 1 propagated along Ti/Pt/Au/SAC305 interface on Si chip side while crack 2 propagated along the solder/IMC interface on AlN HTCC substrate side, which significantly contrasted with prior researches based on FR4 substrate where single cracking typically occurred at one interface. The emergence of two cracks was attributed to tensile stress induced by CTE disparities among different components, including the underfill, which caused two stress interfaces. The FEA results indicated higher stress and strain levels on FR4 substrate compared to AlN, thus facilitating easier crack initiation and more severe crack propagation. The nanoindentation results showed a difference in elastic modulus between the IMC and β-Sn phases, leading to stress concentration during thermal cycling which initiated crack. The increased brittleness of IMC contributed to partial penetration of the crack into the IMC layer during propagation. A strategy to enhance the reliability of the solder joint was also proposed.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417723","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":"The influence of elastic pads deterioration in the fastening system on the dynamic characteristics of the vehicle-turnout system","authors":"Zhaoguang Zheng ,&nbsp;Jiayi Hu ,&nbsp;Yao Qian ,&nbsp;Jingmang Xu ,&nbsp;Mingyang Hou","doi":"10.1016/j.engfailanal.2024.108936","DOIUrl":"10.1016/j.engfailanal.2024.108936","url":null,"abstract":"<div><div>The deterioration of the elastic pads in the fastening system in high-speed turnout areas increases longitudinal stiffness irregularities along the track, posing potential hazards to wheel-rail impact and train running safety. This paper takes the frog area of No. 18 turnout as an example and constructs a vehicle-turnout rigid-flexible coupling model considering the detailed structure of the fastener elastic pads. By increasing the stiffness of the rubber pad under the tie plate to simulate the deterioration of the elastic pads in the turnout area, the study investigates the effects of deterioration location, degree, and number on the dynamic characteristics of the vehicle-turnout system, providing theoretical guidance for stiffness optimization and maintenance of the turnout area. The results indicate that: 1) the deterioration of the elastic pads significantly affects wheel-rail interaction and safety indicators, while having a minor effect on vehicle running stability; 2) the 95th sleeper (point rail with a top width of 60 mm) is identified as the most critical location for the deterioration of elastic pads; 3) comprehensively considering, the stiffness replacement limit for elastic pads in ballastless turnout areas can be set to twice the design stiffness, which is 50 kN/mm.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417721","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 corrosion properties of TA2-Q345 explosive composite plate at different heat treatment temperatures","authors":"Zhen Zhang ,&nbsp;Chenhui Hu ,&nbsp;Jing Li ,&nbsp;Haijun Pan ,&nbsp;Yujie Zhao ,&nbsp;Bojun Zhang ,&nbsp;Lin Liu","doi":"10.1016/j.engfailanal.2024.108944","DOIUrl":"10.1016/j.engfailanal.2024.108944","url":null,"abstract":"<div><div>This study investigated the effects of post-weld heat treatment (PWHT) at 500 °C, 600 °C, 700 °C, and 800 °C on the microstructure and corrosion performance of the TA2-Q345 explosive composite plate, with TA2 as the flyer plate and Q345 as the base plate. X-ray diffraction (XRD), optical microscopy (OM), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) analyses were performed, alongside electrochemical experiments. The explosive welding interface of the TA2-Q345 composite plate exhibited a characteristic wavy structure, which indicated high welding quality. The XRD results indicated that the PWHT temperature significantly affects both the phase structure and the intensity of the diffraction peaks of the oxide film. Additionally, the porosity calculations demonstrated that the sample subjected to PWHT at 500 °C exhibited the lowest porosity in the surface oxide film, resulting in a denser oxide film that effectively enhanced corrosion resistance. However, as the temperature continued to rise, defects such as craters, bulges, and delamination between the oxide film and the titanium matrix were observed. The results of the electrochemical analysis indicated that, compared to untreated samples, the PWHT samples demonstrated improved corrosion resistance. Specifically, the sample with PWHT at 500 °C has the lowest corrosion current density (<em>i</em>_corr) of 6.1892E-06 A/cm², while the untreated sample has the highest <em>i</em>_corr of 6.3577E-05 A/cm², indicating that 500 °C is the optimal temperature. The corrosion process involved the hydrolysis of titanium chloride to form a TiO₂ film and localized corrosion of the TiO₂ protective film. The corrosion products composed of mainly C, O, and Ti were dispersed on the surface of PWHT samples.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417724","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 investigation of an AISI 316L pipe of the flare system in an off-shore oil platform","authors":"F.G.B. Lacerda ,&nbsp;S.S.M. Tavares ,&nbsp;G. Perez ,&nbsp;P.S.P. Garcia ,&nbsp;A.R. Pimenta","doi":"10.1016/j.engfailanal.2024.108939","DOIUrl":"10.1016/j.engfailanal.2024.108939","url":null,"abstract":"<div><div>The oil and gas industries have severe operations conditions, which impose several failures in off-shore equipment. The Flare System is a pipe designed to safely dispose of relieving hydrocarbon gases and liquids during start-up, operational upsets, emergency shutdown, and maintenance activities. This work reported the failure investigation in a pipe of a high-pressure flare system. The pipe has a diameter of 220 mm and 4 mm of thickness, and according to the equipment datasheet, it was made in AISI 316L stainless steel. Two cracks were detected during the previous non-destructive inspection. Those failures were repaired, but another crack was detected after some months. Chemical composition was investigated using optical emission spectroscopy and elemental analysis, and the results are compatible with AISI 316L steel. The microstructure observed by light optical and scanning electron microscopes shows an austenitic matrix with deformation bands. The microhardness measurements and the XRD analysis show the martensite formation in those deformation bands. The tensile properties are in accordance with the standards. The fracture surface was investigated using scanning electron microscopy, the results point to fatigue failure.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417919","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}