Engineering Failure Analysis最新文献

{"title":"Fatigue failure behavior of corrosion water supply steel pipes with void around pipes under long-term service load coupling","authors":"Ying Ma ,&nbsp;Bin Li ,&nbsp;Hongyuan Fang ,&nbsp;Xueming Du ,&nbsp;Niannian Wang ,&nbsp;Danyang Di ,&nbsp;Kejie Zhai","doi":"10.1016/j.engfailanal.2025.109485","DOIUrl":"10.1016/j.engfailanal.2025.109485","url":null,"abstract":"<div><div>Corrosion and void are common defects in the walls and surroundings of water supply steel pipes. Understanding the fatigue failure behavior of steel pipes with combined corrosion and void defects under long-term service loads is essential for assessing their full-service life. This study conducted full-scale fatigue tests on water supply steel pipes with corrosion and void subjected to long-term traffic loads, earth pressure, internal pressure, and groundwater, using an indoor model box testing system. It was observed that the maximum Von Mises strain exhibited slow, rapid, and steady growth as traffic load cycles increased, with a fatigue life of approximately 71.04 million cycles. Subsequently, 3D detailed models of the steel pipe and fluid were established using ABAQUS 6.14–1 and FLUENT 16.0, respectively, and the structural-fluid dynamic coupling was solved through the MpCCI 4.4.2 multiphysics coupling platform. Using the validated FE model, the influence of corrosion length, width, and depth, as well as void position, length, and width, on the fatigue life of the steel pipe was analyzed. Additionally, the longitudinal bending moment and vertical displacement behavior of the pipe at fatigue failure were investigated. It was found that the fatigue life is lowest at the springline, 0.86 and 0.95 times that of the voids at the invert and crown, respectively. As void length, void width, and corrosion length increase from their minimum to maximum design values, the fatigue life of the steel pipe increases by 52%, 45%, and 16%, respectively. However, as corrosion width and depth increase from their minimum to maximum design values, fatigue life decreases by 35% and 54%, respectively. At fatigue failure, the void at the springline results in the smallest longitudinal bending moments and vertical displacements. Both bending moments and displacements increase with increasing void length, width, and corrosion length, while they decrease with increasing corrosion width and depth.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109485"},"PeriodicalIF":4.4,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601406","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 characteristics, failure mechanism and life prediction of copper–aluminum cable joints formed by magnetic pulse crimping","authors":"Shaoluo Wang ,&nbsp;Xiangyu Gao ,&nbsp;Zhiquan Huang ,&nbsp;Hao Jiang ,&nbsp;Guangyao Li ,&nbsp;Junjia Cui","doi":"10.1016/j.engfailanal.2025.109483","DOIUrl":"10.1016/j.engfailanal.2025.109483","url":null,"abstract":"<div><div>Magnetic pulse crimping process has significant potential for high-voltage cable joint manufacturing due to its green, eco-friendly, efficient, and reliable advantages. In this paper, the fatigue characteristics and fracture behaviors of Cu-Al dissimilar cable joints prepared by magnetic pulse crimping (MPC) and hydraulic crimping (HC) were explored and compared. The fatigue life prediction models for the two cable joints at different reliability levels were developed. The contact resistance change features, crack propagation laws and fatigue failure mechanisms of cable joints were revealed. Results showed that the failure modes of cable joints at different stress levels could be divided into Al harness fracture (<em>S</em>_M ≥ 45.7 MPa), Cu terminal fracture (<em>S</em>_M &lt; 34.3 MPa), and mixed fracture of the two (<em>S</em>_M = 34.3 MPa). As the stress level decreased, the fatigue life of cable joints gradually increased, and the failure mode gradually transitioned from Al harness fracture to Cu terminal fracture. The contact resistance of MPC and HC cable joints presented opposite changes during the fatigue process. Fretting wear at the Al-Cu contact generated Al₂O₃ particles. The initial fatigue cracks mainly initiated at the surface damage of Al harness in the crimping area and at the intersection of the tube end and the plate end on the upper surface of Cu terminal. Because there were significant stress concentrations at these two locations. The fatigue fractures all had typical crack initiation zones, crack propagation zones and instantaneous fracture zones.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109483"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552159","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 delayed cracks in heavy forged steel rolls for reduction gears","authors":"Ihho Park,&nbsp;Won-Jon Yang,&nbsp;Jae Hoon Jang","doi":"10.1016/j.engfailanal.2025.109481","DOIUrl":"10.1016/j.engfailanal.2025.109481","url":null,"abstract":"<div><div>Hydrogen-induced cracking in heavy forged steel rolls was investigated to understand the damage mechanisms in cracked roller products. Cracks, initially observed several weeks after manufacturing, were found in the central band (A-type segregation region) of the roll, characterized by hairline cracks several millimeters in size. Microstructural analysis revealed an increased number of MnS inclusions at the crack sites, with these inclusions being larger in size and more abundant compared to other regions of the roll. Thermodynamic calculations and hydrogen pressure estimations were performed to model the conditions under which cracks propagate, particularly when hydrogen accumulates at the interface between MnS inclusions and the surrounding matrix. When the sulfur content was 0.003 wt%, cracks were predicted to occur when MnS inclusions exceeded approximately 1.3 µm in size.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109481"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561558","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 prediction of wind turbine tower considering the effect of high-tension bolt failure","authors":"Yuka Kikuchi,&nbsp;Takeshi Ishihara","doi":"10.1016/j.engfailanal.2025.109494","DOIUrl":"10.1016/j.engfailanal.2025.109494","url":null,"abstract":"<div><div>In this study, an accident at Taikoyama wind farm is investigated by the fatigue analysis of high-tension bolts and tower. Firstly, a sophisticated aeroelastic model is proposed by identifying the structural and control parameters and validated with the measured tower base bending moment. The predicted bending moment at the tower top shows that the tensile stress occurs at the downwind side of tower due to the eccentricity of the centre of gravity of rotor and nacelle. The bolt axial force is then predicted using the finite element model of the tower top with consideration of effects of ball bearings, yaw breaks and pinion gear. The predicted bolt fatigue life is about three months when the residual bolt axial force is less than 30 %, which matches the maintenance record. Finally, the stress of the tower shell is investigated by a sophisticated FEM model. It is found that the tensile stress is generated inside of the tower shell due to the leverage effect. The relationship between the local stress and the nominal stress shows the nonlinearity and the local stress in the case with damaged bolts is three times larger than that in the case with intact bolts. The predicted fatigue life of the tower favourably agrees with the observation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109494"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637312","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":"Investigating hunting stability failure in a high-speed locomotive: A comparative analysis of evaluation methods for typical worn wheel treads","authors":"Hu Li ,&nbsp;Tong Tan ,&nbsp;Sebastian Stichel ,&nbsp;Yuan Yao","doi":"10.1016/j.engfailanal.2025.109482","DOIUrl":"10.1016/j.engfailanal.2025.109482","url":null,"abstract":"<div><div>Hunting stability is a critical factor affecting high-speed locomotives dynamic performance, inherently connected to wheel-rail contact geometry. Tread wear typically increases the nonlinearities in the contact geometry, causing stability disparities. Previous studies on stability have often overlooked these nonlinear aspects, which can be captured by the equivalent conicity function. In this study, the equivalent conicity functions of worn wheel treads are systematically categorized into six distinct classes. This classification allows for a comprehensive evaluation of their respective influence on hunting stability failure, enabling the analysis of stability characteristics of typical worn wheel treads. The limited research available on three-axle bogies motivate the selection of a locomotive equipped with such bogies as the basis for framework, aiming to bridge the gap in existing literature. Based on different stability evaluation methods, theoretical, small-amplitude hunting, and engineering critical speeds have been determined. The observed differences in different critical speeds from the perspective of equivalent conicity function are elucidated. The results show that a high equivalent conicity at small displacement can significantly reduce the theoretical critical speed, and therefore, the engineering critical speed is recommended as a criterion for stability assessment and optimization. Moreover, the Driving Energy Loss Ratio (DELR), a metric assessing both primary and secondary hunting stability, is developed to evaluate the stability of self-excited vibrations. This research provides guidance for the evaluation and optimization of railway vehicle stability.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109482"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561682","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 behaviours of steel/aluminium threaded connections under impact fatigue","authors":"Chenxu Zhang ,&nbsp;Ruoheng Sun ,&nbsp;Jianping Yin ,&nbsp;Yilun Hu ,&nbsp;Qingbo Dou ,&nbsp;Zhongbin Tang ,&nbsp;Yinggang Miao ,&nbsp;Yulong Li","doi":"10.1016/j.engfailanal.2025.109473","DOIUrl":"10.1016/j.engfailanal.2025.109473","url":null,"abstract":"<div><div>Threaded connections work as essential components in engineering structures, covering multiple industries such as aerospace and construction. However, they are frequently exposed to complex loadings of dynamic and impact loads, which even result in unexpected fatigue failure. In this study, we modify Hopkinson tension bar technique by guiding stress wave reflection, to achieve controllable cyclically loading threaded fasteners under impact fatigue. Specimen of steel-aluminum threaded connection is specifically designed for focusing on mere aluminum thread failure. Impact fatigue of 1 kHz around are successfully conducted, enabling to precisely determine mechanical behaviors of each cyclic and impact fatigue life under varying tensile loads. It is demonstrated that, its impact fatigue life is strongly dependent on loading stress amplitude. More importantly, irreversible damage occurring in threads, presents in the overall linear-elastic phase of the connection under impact fatigue loading, leading to progressive degradation of mechanical properties and eventual failure. Failure mode is predicted experimentally and verified by finite element simulated results, of uneven load/stress distribution across threads where higher stress concentrations occur near thread root, making them more susceptible to failure and progressive degradation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109473"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552221","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 elastoplastic semi-analytic solution of a timely active support technique using NPR bolts for deeply-buried tunnels","authors":"Hongru Li ,&nbsp;Manchao He ,&nbsp;Yingming Xiao ,&nbsp;Shulin Ren ,&nbsp;Congling Shi","doi":"10.1016/j.engfailanal.2025.109477","DOIUrl":"10.1016/j.engfailanal.2025.109477","url":null,"abstract":"<div><div>The timely active support technique using high-strength, high-toughness negative Poisson’s ratio (NPR) bolts as the key material (NPR-TAST) has a positive effect on disaster control in deeply buried tunnels. In this study, based on the finite difference method, a semi-analytical solution for NPR-TAST is proposed to investigate the effect of NPR bolts on ground reactions. The stress relief coefficient method is adopted to simulate the unloading process and the interaction process between the bolts and surrounding rock. Once the bolt deformation exceeds the set maximum value, the bolt would break. The proposed solution is validated by the previous semi-analytical and numerical solutions. The results show that, under large deformation conditions, conventional bolts tend to break. In contrast, NPR bolts can continuously deform with the surrounding rock, enhancing the bearing capacity of the surrounding rock. The key factors of NPR-TAST, including support timing, pre-stress magnitude, and constant resistance value of NPR bolts, are discussed. Early application of higher pre-stressed NPR bolts and increasing the constant resistance value of these bolts can more effectively control surrounding rock deformation and failure. The research results can provide guidance for the application of NPR-TAST in deeply buried tunnels.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109477"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561747","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 study of diesel engine deposits on failure of honed cylinder liner surface texture","authors":"Daigeng Wu ,&nbsp;Xingyu Liang ,&nbsp;Xue Wen ,&nbsp;Zhongwei Meng ,&nbsp;Zehui Yu ,&nbsp;Yongdi He ,&nbsp;Peng Dai ,&nbsp;Yonglin Yu ,&nbsp;Nan Li","doi":"10.1016/j.engfailanal.2025.109476","DOIUrl":"10.1016/j.engfailanal.2025.109476","url":null,"abstract":"<div><div>Studying the wear of cylinder liner and piston ring caused by deposits helps improve engine reliability. Deposits generated from a coastal diesel engine are collected, including impurity deposits from intake duct (#1) and carbon deposits from piston (#2), piston ring (#3), and cylinder liner top (#4). Using reciprocating friction tester, the influence of #1 and #2 on surface wear is studied under varying oil film thicknesses. Then combining Inductively Coupled Plasma Mass Spectrometer (ICP-MS), Thermogravimetric Analysis (TGA), and Scanning Electron Microscope (SEM) to explore potential wear mechanism. Results show that insufficient lubrication and the presence of intake duct deposits are the two main causes of wear. Under low oil film thickness (Oil-L), a transition from good to poor lubrication occurs, leading to increased wear. Adding deposits significantly increases the coefficient of friction (COF). However, insufficient lubrication poses higher wear risks than the absence of lubrication. Among them, ‘#1 + Oil-L’ exhibits the most severe wear, with the COF rising from 0.530 (#1 only) to 0.619 and producing the deepest scratch of 32 μm. This severe wear after adding #1 correlates with a higher proportion of sand and metal shown in physicochemical analysis, as well as the needle-like Fe₂O₃ corrosion products observed after TGA oxidation. Additionally, this study also discusses the possible reasons for insufficient lubrication and the potential effect of detected lubricant contamination in this engine. Enhancing engine lubrication and controlling intake impurities are critical strategies to mitigate abnormal honing texture wear.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109476"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561748","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 bio-mimicked surface texturing on the shear strength of additively manufactured metal single-lap joints: An innovative approach","authors":"M. Gokhan Atahan ,&nbsp;Ian Maskery ,&nbsp;Ian Ashcroft ,&nbsp;M. Kemal Apalak ,&nbsp;Athanasios Pappas","doi":"10.1016/j.engfailanal.2025.109460","DOIUrl":"10.1016/j.engfailanal.2025.109460","url":null,"abstract":"<div><div>In this paper, we investigate the mechanical performance of metal single-lap joints featuring bio-mimicking surface textures. The inspiration for the surface textures was the foot and toe of the gecko, a creature whose ability to climb smooth shear surfaces is attributed to the meso- and micro-structures of its feet. Three surface textures were investigated: a hexagonal texture based on the central region of the foot, a lamellae-like texture based on the toe, and a mixed texture of both. Metal adherends with these textures were produced using the laser powder bed fusion (LPBF) additive manufacturing method. Finite element analysis was performed to examine the influence of surface texture on stress distribution in the adhesive layer, while mechanical testing was used to determine joint strength and failure mode. Compared to the as-printed surface texture, bio-mimicking surface textures improved the wettability of the bonding surfaces, and significantly improved the lap shear strength of the joints. Mechanical interlocking due to surface texture was more effective than the increase in bonding surface area in enhancing joint strength. The bio-mimicking textures improved the damage tolerance capacity of the joints by reducing local stress concentrations at the overlap edges of the adhesive layer and ensured that the adhesive failure type was mixed mode due to the mechanical interlocking effect. The presented novel bio-mimicked surface texture method offers promising results for both industrial applications and scientific studies.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109460"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552219","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 limited annotated sample fault diagnosis algorithm based on nonlinear coupling self-attention mechanism","authors":"Shuyang Luo ,&nbsp;Dong Zhang ,&nbsp;Jinhong Wu ,&nbsp;Yanzhi Wang ,&nbsp;Qi Zhou ,&nbsp;Jiexiang Hu","doi":"10.1016/j.engfailanal.2025.109474","DOIUrl":"10.1016/j.engfailanal.2025.109474","url":null,"abstract":"<div><div>Deep learning-based intelligent diagnostic algorithms are regarded as a technology with significant industrial application prospects. However, acquiring sufficient annotated samples for training remains challenging in practice application, rendering the model susceptible to overfitting. To tackle the issue, a semi-supervised learning algorithm based on nonlinear coupling self-attention mechanism (NCSAM) is proposed for fault diagnosis with scarce annotated samples. Specifically, the method combines a pre-training model using multi-scale convolutional autoencoder (MSCAE) with a novel pre-training approach based on signal transformation to extract generic features from an ample number of unlabeled samples. On this basis, a nonlinear coupling self-attention mechanism is designed to adaptively explore both linear and nonlinear information in input data, achieving the integration of multi-scale features. Finally, the fault classification is completed using a linear classifier. The effectiveness of the proposed method has been validated on two public datasets. The results demonstrate that even with extremely limited annotated samples, the method achieves an accuracy of 97.83%, a 4.74% improvement over the baseline. Additionally, extensive comparative experiments with both semi-supervised and supervised algorithms have been designed to confirm the advantages of the proposed approach. In contrast, the diagnostic performance of the proposed method surpasses that of other methods.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109474"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552220","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}