Engineering Failure Analysis最新文献

{"title":"Prediction of statistical force–displacement curves of Charpy-V impact tests based on unsupervised fracture surface machine learning","authors":"Johannes Rosenberger ,&nbsp;Johannes Tlatlik ,&nbsp;Nils Rump ,&nbsp;Sebastian Münstermann","doi":"10.1016/j.engfailanal.2025.109551","DOIUrl":"10.1016/j.engfailanal.2025.109551","url":null,"abstract":"<div><div>While conventional pendulum impact tests only measure a material’s integral energy absorption, the instrumented version of the test provides valuable additional insights by extracting force–displacement behaviour of the loaded specimen. The latter, however, requires auxiliary testing equipment, calibration procedures and evaluation methods. Therefore, this study aims to predict force–displacement behaviour of instrumented Charpy impact tests solely on the basis of analyzing images of specimen fracture surfaces postmortem. This is explored and achieved by using unsupervised machine learning techniques for computer vision. By using unsupervised computer vision on fracture images from 4 steels, we assess the feasibility of classifying fracture surfaces and deriving statistical force–displacement curves and provide crucial interpretability of the model’s decision making. The results indicate the model’s ability to learn the necessary representations without the need of supervision. The unsupervised model can extract significant insights from fracture images alone, supporting efficient, accurate, and interpretable materials testing, where confidence intervals of 97 % can already be met for the upper shelf. This allows detailed information about the mechanical behaviour of the material to be obtained from non-instrumented tests.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109551"},"PeriodicalIF":4.4,"publicationDate":"2025-03-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687829","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":"Microstructure, hardness, and tribological properties of AA2014 powder metallurgy alloys: A sizing mechanical surface treatment study","authors":"Nima Valizade ,&nbsp;George Jarjoura ,&nbsp;Georges J. Kipouros ,&nbsp;Kevin Plucknett ,&nbsp;Sajad Shakerin ,&nbsp;Mohsen Mohammadi","doi":"10.1016/j.engfailanal.2025.109550","DOIUrl":"10.1016/j.engfailanal.2025.109550","url":null,"abstract":"<div><div>This study explores the influence of sizing mechanical surface treatment on the tribological response of AA2014 powder metallurgy (PM) alloy-steel tribosystem under reciprocating sliding wear. The impact of sizing pressure on wear mechanisms is analyzed using a combination of X-ray diffraction (XRD), electron backscatter diffraction (EBSD), surface topography, hardness testing, wear rate measurements, and microscopic analyses. The results show that sizing treatment can significantly alter wear mechanisms, shifting from abrasion and mild oxidative wear to delamination and cracking, especially at lower sizing pressures. Samples sized at 200 MPa and 300 MPa displayed pronounced delamination and cracking. In contrast, increasing the sizing pressure to 400 MPa enhanced mechanical properties, reduced the wear rate, and minimized delamination. This suggests that although sizing with relatively low sizing pressure can increase hardness, it may detrimentally affect the alloy’s wear performance by intensifying stress concentration effect. However, wear properties benefit from the superior mechanical properties gained through cold working of the alloy at a higher pressure of 400 MPa. This research highlights the critical role of sizing pressure in optimizing the tribological performance of sized aluminum PM alloys.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109550"},"PeriodicalIF":4.4,"publicationDate":"2025-03-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687661","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":"Cavitation failure analysis and mechanism study of the wet cylinder liner in heavy-duty diesel engines","authors":"Dong Liu ,&nbsp;Lintao Li ,&nbsp;Guoxing Li ,&nbsp;Nannan Sun ,&nbsp;Guixiang Zhu ,&nbsp;Tie Wang ,&nbsp;Fengshou Gu","doi":"10.1016/j.engfailanal.2025.109547","DOIUrl":"10.1016/j.engfailanal.2025.109547","url":null,"abstract":"<div><div>Cavitation failure of the cylinder liner is one of the main reliability problems in heavy-duty diesel engines. It can shorten engine lifespan, increase maintenance costs, and even lead to catastrophic failures. This paper conducts a systematic study of cylinder liner cavitation by integrating microstructure analysis, cavitation process observation, and numerical simulation. The morphology and chemical composition of the damaged regions are analysed at both macro and micro levels, providing comprehensive insights into the cavitation erosion behaviour and damage mechanisms. The vibration and pressure fluctuation characteristics of the cylinder liner-water jacket system are investigated by a structure-acoustic coupling model. The predicted cavitation risk regions of the cylinder liner are in good agreement with the actual cavitation erosion regions. Cavitation damage is primarily concentrated within a 26 mm vertical zone adjacent to the lower seal of the cylinder liner. The minimum pressure in the water jacket occurs at 373.3 °CA. When the engine speed exceeds 1400 rpm, the risk of cavitation arises and progressively intensifies with increasing speed and load. The results enrich the theoretical system of cavitation erosion in cylinder liners and provide a valuable reference for the cavitation prediction and mitigation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109547"},"PeriodicalIF":4.4,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687757","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure mechanisms of prefabricated multi-family buildings under gas explosions","authors":"Piotr Knyziak","doi":"10.1016/j.engfailanal.2025.109548","DOIUrl":"10.1016/j.engfailanal.2025.109548","url":null,"abstract":"<div><div>Large-panel buildings are multi-story structures made of prefabricated large-sized wall and floor panels, where the integrity of connections between elements plays crucial role in structural integrity. Under gas explosions, these structures exhibit specific failure mechanisms that differ from those of monolithic slab-column systems. The potential for preventing progressive collapse in large-panel buildings depends on the arrangement of load-bearing walls, the effectiveness of alternative load paths, and the resistance of structural ties. Despite adherence to modern safety standards, unexpected structural failures still occur, highlighting the need for a deeper understanding of these mechanisms.</div><div>This study examines real cases of gas explosions in large-panel buildings, identifying three primary failure mechanisms. Type 1 – local damage limited to a one room (usually the kitchen), with limited structural impact on adjacent elements. Type 2 – damage to the entire apartment, potentially leading to progressive collapse depending on tie resistance. Type 3 – High-energy explosions in basements or extensive areas of gas saturation, often causing progressive collapse and significant structural damage. Analysis reveals that spatially appropriately shaped cross-wall construction systems significantly improve structural resilience by enhancing alternative load paths and reducing progressive collapse probability. Additionally, structural damage severity correlates with energy and extent of the explosion, which is consistent with modern technical standards.</div><div>The findings contribute to a more comprehensive understanding of how large-panel buildings behave under gas explosion overpressure, emphasizing the importance of proper reinforcement detailing, high-quality workmanship, and periodic inspections to detect corrosion or weakened connections. The study provides practical recommendations for improving design strategies, maintenance practices, and safety measures to prevent or mitigate progressive collapse. These insights are critical for enhancing the long-term safety and resilience of large-panel residential buildings, ensuring their continued usability under both normal and extreme conditions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109548"},"PeriodicalIF":4.4,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687800","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":"Exploring failure mechanisms in reinforced concrete slab-column joints: Machine learning and causal analysis","authors":"A. Ӧzyüksel Çiftçioğlu","doi":"10.1016/j.engfailanal.2025.109549","DOIUrl":"10.1016/j.engfailanal.2025.109549","url":null,"abstract":"<div><div>Reinforced concrete slab-column construction comprises interconnected slabs and columns that constitute the structural system of a building. While providing architectural flexibility and ease of construction, these types of structures are prone to failure because the structural arrangement beneath the slabs is not always considered thoroughly. This research uses machine learning models to conduct an in-depth study and categorizes failure modes into three main types: flexure, punching, and combined flexure-punching modes. These failure modes are classified with appreciable accuracy by eight machine learning approaches: RAGN-L, Random Forest, Extra Trees, K-Nearest Neighbors, Adaptive Boosting, Support Vector Machine, Logistic Regression, and Gaussian Naive Bayes classifiers, optimized using hyperparameter tuning. The results indicate that the RAGN-L achieves the highest accuracy at 0.99, followed by the Random Forest model with an accuracy of 0.98. The study extends the machine learning analysis by investigating the deep causes that rule the complex interactions among key structural parameters. SHAP analysis revealed the influence of features like slab thickness, reinforcement ratio, and punching shear strength on failure modes. Counterfactual analyses further revealed how changes in these parameters can change failure modes and indicate their sensitivity and robustness. The results imply that reducing or optimizing certain parameter values will change the sample types and thus make them change between failure modes. By combining machine learning, SHAP analysis, causal analysis, and counterfactual methods, this study offers valuable insights into the failure mechanisms of slab-column joints and provides actionable recommendations to enhance structural safety and reliability.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109549"},"PeriodicalIF":4.4,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687756","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":"Dynamic reliability analysis of the bushings’ base fracture of a 220 kV transformer-bushing system subjected to fully nonstationary earthquake loads","authors":"Mingjun Wang ,&nbsp;Yinghao Duan ,&nbsp;Jun He","doi":"10.1016/j.engfailanal.2025.109539","DOIUrl":"10.1016/j.engfailanal.2025.109539","url":null,"abstract":"<div><div>The high-voltage (HV) transformers, primarily composed of the oil tank and porcelain bushings, are vulnerable to earthquake damage and prone to fracture at the base of the porcelain bushings. The dynamic reliability analysis of HV transformer bushing base fracture involves calculating the small first passage probabilities for nonstationary wide-banded random seismic responses exceeding the high threshold levels. Existing methods for addressing this issue are either inefficient or impractical. To efficiently estimate the small first passage probabilities, this paper proposes a tail decay rate and multiple support points-based shifted generalized lognormal distribution (SGLD) model method. The method formulates the parameter estimation for the SGLD as an optimization problem with a constraint, enabling rapid parameter estimation. To implement, the objective function is formulated to minimize the mean absolute percentage error of failure probabilities, incorporating multiple support points to enhance the comprehensive utilization of simulation samples. Furthermore, the constraint is introduced concerning the hypothesis of near-linear behavior in the tail region corresponding to small failure probabilities, wherein the slope of the asymptotically correct first passage probabilities calculated by the crossing approach approximates the actual slope. The dynamic reliabilities of the porcelain bushings’ base fracture of a 220 kV auto-transformer subjected to the fully nonstationary El-Centro-like earthquake load are analyzed utilizing the proposed method. The analysis demonstrates the application process and efficiency of the proposed method and provides seismic design recommendations for this kind of transformers.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109539"},"PeriodicalIF":4.4,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687755","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 the impact of damage and strengthening of a steel spirit tank over its long lifetime","authors":"Sandra Mlonek,&nbsp;Monika Mackiewicz,&nbsp;Tadeusz Chyży","doi":"10.1016/j.engfailanal.2025.109546","DOIUrl":"10.1016/j.engfailanal.2025.109546","url":null,"abstract":"<div><div>Steel tanks for liquids are objects of great importance from the point of view of industrial development. They are often used for a considerable period of time and then the significant problem of assessing their technical condition arises. Previous repairs and strengthening are also important and should always be taken into account. As the tank wears out, the risk of an unexpected failure increases. The problem is whether only monitoring of the structure and the lack of significant deformation increase can be treat as a sufficient confirmation of further safe operation of the tank?</div><div>The aim of the presented research was to analyze the usefulness of the conducted assessment of the technical condition of the facility in terms of its further safe use. The article presents the results of the thorough analysis of the steel tank technical condition, which constitute the basis for further recommendations and guidelines for safe use. The analysis used available technical documentation including all previous inspections. Deformation measurements were carried out and the extent of damage to the tank was determined. The necessary conditions for its further possible operation were determined. Computer simulations of the tank were carried out, which showed that the proposed solutions would allow for further safe operation of the tank. The article includes the results of the FEM (Finite Element Method) computational analysis.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109546"},"PeriodicalIF":4.4,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143705333","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":"Vibration induced fatigue of mining and material handling mega machines","authors":"Przemysław Moczko,&nbsp;Maciej Olejnik,&nbsp;Damian Pietrusiak,&nbsp;Jędrzej Więckowski","doi":"10.1016/j.engfailanal.2025.109529","DOIUrl":"10.1016/j.engfailanal.2025.109529","url":null,"abstract":"<div><div>The article presents the current progress of research and development in of mining and material handling machines and focuses on estimation of the actual loads acting on the discussed objects, especially in the area of their undercarriage. In many cases, the standards currently used miss the case of verification fatigue scenario, or the values adopted are much lower than those observed during operation. The following paper briefly describes the possible consequences of failure in the machines described in article, the current approach of standards to fatigue, and the current progress of research and development in the context of fatigue calculations with respect to the alternating loads acting on the undercarriage. The described research will allow in the future to update the existing calculation standards or propose additional activities during the design of mining and material handling mega machines. This will allow for better optimization of the structure in terms of its resistance to fatigue damage.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109529"},"PeriodicalIF":4.4,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697180","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":"A novel analytical approach for 3D stability of unsaturated soil slopes with cracks under rainfall infiltration","authors":"Lei Zhang ,&nbsp;Xin Jiang ,&nbsp;Rong Sun ,&nbsp;Canyang Cui ,&nbsp;Hanyan Gu ,&nbsp;Yanjun Qiu","doi":"10.1016/j.engfailanal.2025.109545","DOIUrl":"10.1016/j.engfailanal.2025.109545","url":null,"abstract":"<div><div>Rainwater infiltration in unsaturated soil slopes with crest cracks can trigger two distinct three-dimensional (3D) failure modes: shallow translational failure along the slope face and deep-seated rotational failure at the crack tip. This study employs the upper-bound limit analysis method to present an analytical framework for the 3D stability analysis of unsaturated soil slopes with cracks under rainfall infiltration. Two kinematically admissible failure mechanisms are constructed: a novel composite mechanism combining a 3D horn-shaped block with an oblique cylinder to characterize translational failure, accounting for boundary effects at slope crest, toe, and lateral constraints; and a rotational failure mechanism based on the horn-shaped block. The wetting front model is adopted to capture the transient process of rainwater infiltration. The proposed method enables a unified evaluation of both shallow and deep-seated stability for slopes with arbitrary crack depths at the crest, and its effectiveness is validated by existing literature. Parametric studies are conducted to investigate the effect of slope geometry (width-to-height ratio) on stability and the controlling factors of the translational and rotational failures.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"175 ","pages":"Article 109545"},"PeriodicalIF":4.4,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143681992","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":"Clamping anti-derailment devices for high-speed trains","authors":"Fengqi Guo ,&nbsp;Yang Bai ,&nbsp;Liqiang Jiang ,&nbsp;Jiawei Qin ,&nbsp;Lizhong Jiang","doi":"10.1016/j.engfailanal.2025.109540","DOIUrl":"10.1016/j.engfailanal.2025.109540","url":null,"abstract":"<div><div>Ensuring the stability of high-speed trains under earthquake or crosswind hazards is essential for maintaining operation safety. Traditional anti-derailment methods, like guardrails and barrier walls, require extensive construction, leading to high costs and only take effect after the derailment. This study proposes a novel solution involving Clamping Anti-Derailment Device (CADD) mounted on train bogies to catch the track in hazardous conditions. Seven full scale CADD prototypes underwent monotonic pull-out loading tests, and a numerical model was developed to analyse their failure mechanisms. After model validation, parametric analyses were performed, and a theoretical model was established to simplify the load–displacement relationship of the devices. Additionally, a train-track dynamic model was constructed to assess the CADD performance under wind loads. The results showed that: (1) A CADD can provide 131.10 kN, and a pair of devices installed on each bogie is sufficient to resist the self-gravity of a single car. (2) The primary failure mode was the outward expansion of cantilever hook plate’s bottom end, causing no damage to the rail or bogie; (3) Under a 25 m/s crosswind at 350 km/h, the derailment coefficient decreased by 16.25 %. and under a 20 m/s crosswind at same speed, the wheel load reduction rate decreased by 8.16 %. The results demonstrate the potential of the CADD to enhance the safety and stability of high-speed trains under extreme conditions. Furthermore, a theoretical load–displacement model for the CADD was derived, providing a basis for future updates to the wheel-rail contact relationship in train-track-bridge coupled systems incorporating novel CADD.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109540"},"PeriodicalIF":4.4,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687751","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}