Engineering Failure Analysis最新文献

{"title":"The effects of cracks on the failure mechanisms, mechanical properties, and fatigue behaviors of steel/aluminum SPR joints","authors":"Qinghui He ,&nbsp;Chao Chen","doi":"10.1016/j.engfailanal.2025.109854","DOIUrl":"10.1016/j.engfailanal.2025.109854","url":null,"abstract":"<div><div>In the modern automotive industry, lightweighting is a major development trend, and the joining of dissimilar materials like steel and aluminum has become a key solution for vehicle body structures. Self-piercing riveting (SPR) is widely applied in joining dissimilar materials, offering stable SPR joint strength and fatigue performance. However, when the base materials exhibit low elongation, cracks may in SPR joints. In this paper, 22MnB5 steel and AL6061-T6 aluminum were selected as the joining materials. The mechanisms of neck and head crack formation in SPR joints were investigated through cross-sectional analysis and metallographic observation. The results show that reducing the die depth effectively suppresses crack initiation in SPR joints. Shear tests revealed that neck cracks significantly reduce the SPR joint strength. Furthermore, fatigue tests were carried out on SPR joints with and without head cracks, and the fatigue fracture surfaces were analyzed. The results indicate that head cracks have a negligible influence on fatigue performance, with both types exhibiting comparable fatigue life.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109854"},"PeriodicalIF":4.4,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144572324","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure Analysis of Sulfur Solidification 2205 Duplex Stainless Steel Conveyor Belt","authors":"Mahmoud T. Abdu ,&nbsp;Maiada S. Abdelrahman ,&nbsp;Waleed Khalifa","doi":"10.1016/j.engfailanal.2025.109851","DOIUrl":"10.1016/j.engfailanal.2025.109851","url":null,"abstract":"&lt;div&gt;&lt;div&gt;A sulfur solidification 2205 duplex stainless steel conveyor belt failed after 5 months of service. A detailed failure analysis was conducted to reveal the main cause of failure. The investigation included visual inspection, complete microstructural characterization and tensile testing. The study revealed that the main cause of failure was fatigue cracking. During installation, uncontrolled torch treatment was used to straighten wavy belt edges. This treatment led to the formation of intermetallic phases, carbide/oxide clusters, and residual stresses. Furthermore, the low nitrogen (N) content of the DSS belt promoted the formation of both intermetallic phases and carbide clusters. N is an austenite stabilizer, so low N decreases the amount of austenite and increases the ferrite phase, which is a preferential site for the formation of intermetallic phases and carbides. Interestingly, belt misalignment occurred, despite the presence of a self-alignment system, and combined with torch treatment to promote fatigue crack initiation and propagation. The existence of hard (α) and soft (ϒ) phases assisted fatigue crack initiation and propagation via α/ϒ separation boundaries, transgranular cracking, and accumulation of plastic deformation at the boundaries. Thus, this failure analysis proposed a possible fatigue failure mechanism for the 2205 DSS, which is considered unclear and is still an active research area. Moreover, there has not been any published literature on similar failure cases that encompass the combined effects of uncontrolled thermal repair, misalignment, and low nitrogen content on the fatigue cracking behavior of DSS conveyor belts in sulfur solidification environments, which emphasizes the novelty of this work. It is recommended to strictly follow the specified procedure for the installation and maintenance of DSS belts. A period of 2–3 weeks should be sufficient for regular maintenance. The optimal maintenance procedure should include regular cleaning of dirt, oil, grease, or any debris; appropriate examination for wear and tear; regular inspection for belt tension to prevent over-tensioning or slippage; systematic checks for alignment of the conveyor frame, drums and rollers; and proper inspection for alignment of the edge-seal support system. The conveyor system should employ center-to-center distances according to the pulley sizes and belt length, edge-seal support systems, belt trackers, belt scrapers, rigid and stable support systems, proper roller material, and closely stacked idle pulleys. Furthermore, the best 2205 DSS properties and minimum amounts of intermetallic phases should be ensured when the Cr, Mo, and N contents are within the upper half of the acceptable range. Therefore, the contents of Cr, Mo, and N should be at least 22–23 wt%, 3–3.5 wt%, and 0.14–0.2 wt%, respectively. The use of postrepair heat treatment is strongly not recommended. Additionally, it would be better to use other belt materials, such as ","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109851"},"PeriodicalIF":4.4,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518167","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":"Crack suppression and ductility modification of additive manufactured Ti6Al4V/W heterostructure interface via Nano-TiC reinforcement","authors":"Xianglong Dai ,&nbsp;Quanlong Wu ,&nbsp;Xue Li ,&nbsp;Xiaoqiang Wang ,&nbsp;Yuxuan Shi ,&nbsp;Yan Zhou ,&nbsp;Shifeng Wen ,&nbsp;Yusheng Shi","doi":"10.1016/j.engfailanal.2025.109852","DOIUrl":"10.1016/j.engfailanal.2025.109852","url":null,"abstract":"<div><div>The incorporation of titanium alloy Ti-6Al-4 V (TC4) and tungsten (W) into hybrid structures presents considerable potential for utilization in extreme environments. However, challenges such as interfacial brittleness, residual stresses, and limited metallurgical compatibility impede effective bonding. In this study, laser powder bed fusion (L-PBF) was employed to fabricate TC4/W bimetallic heterostructures, with nano-TiC particles introduced at the interface to improve interfacial bonding and mechanical performance. Experimental findings indicate that the addition of nano-TiC effectively reduces interfacial defects, refines grain structure by decreasing the average grain size by 16.7–27.5 %, and facilitates the formation of β-Ti/W infinite solid solutions with fully coherent interfaces. These microstructural enhancements lead to significant improvements in mechanical properties, as evidenced by an increase in ultimate tensile strength (UTS) from 600 MPa to 725 MPa and an improvement in elongation (EL) from 6.8 % to 10.3 %. The observed strengthening mechanisms primarily result from grain boundary refinement, dislocation pinning, and Orowan strengthening effects. The findings of this study present a feasible approach for optimizing additive-manufactured TC4/W composites to meet the stringent demands of aerospace and nuclear applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109852"},"PeriodicalIF":4.4,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144548448","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 identification and collapse mechanisms of unreinforced masonry Heritage: A comprehensive study of Erzurum Atatürk House","authors":"Dilek Okuyucu ,&nbsp;Tümer Eslek ,&nbsp;Dursun Burak Özdoğan ,&nbsp;Tuğçe Laçin ,&nbsp;Ömer Mercimek ,&nbsp;İrfan Kocaman","doi":"10.1016/j.engfailanal.2025.109850","DOIUrl":"10.1016/j.engfailanal.2025.109850","url":null,"abstract":"<div><div>This study presents a comprehensive seismic assessment of the historical Erzurum Atatürk House, a representative example of unreinforced masonry (URM) structures in Turkey’s high-seismicity region. The research combines experimental and numerical approaches, including operational modal analysis (OMA), detailed finite element modeling, and nonlinear dynamic analyses using nine recorded ground motions. The OMA identified the structure’s first three natural frequencies at 3.458 Hz (N-S translation), 3.984 Hz (E-W translation), and 4.264 Hz (torsional mode), with MAC values exceeding 0.9, confirming the accuracy of the calibrated numerical model. Nonlinear time-history analyses revealed critical vulnerabilities, with peak displacements exceeding acceptable limits for all considered seismic scenarios (including 2023 Kahramanmaraş earthquakes). The structure exhibited brittle failure mechanisms characterized by Rapid stiffness degradation; Significant tensile cracking at wall-floor junctions; Out-of-plane failures in upper-story walls; Diagonal shear band formations. Material characterization showed low tensile (0.3–1.07 MPa) and compressive (3–10.71 MPa) strengths, typical of historical masonry with weak lime-based mortars. The force–displacement relationships demonstrated limited energy dissipation capacity, with strength degradation occurring at approximately 10,000 kN lateral load. These findings provide fundamental insights into the seismic behavior of historical URM buildings and establish a methodological framework for their assessment. The study highlights the critical need for further research on performance-based evaluation methods for cultural heritage structures in seismic zones.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109850"},"PeriodicalIF":4.4,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144534696","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":"Towards the classification and numerical prediction of fracture patterns in float glass using peridynamics","authors":"Konstantin Naumenko ,&nbsp;Oleksiy Larin ,&nbsp;Olha Sukhanova ,&nbsp;Matthias Pander","doi":"10.1016/j.engfailanal.2025.109802","DOIUrl":"10.1016/j.engfailanal.2025.109802","url":null,"abstract":"<div><div>The strength of float glass is influenced by surface flaws introduced during processing and transportation, leading to varied fracture patterns under identical loading conditions. While previous studies use fracture mechanics to predict damage initiation based on flaw distribution, a systematic analysis of fracture patterns remains lacking. This study classifies fracture patterns from co-axial ring bending tests based on damage initiation type and location. Additionally, peridynamic theory is employed to model damage evolution using three approaches: (1) a quasi-homogeneous plate with an average critical bond stretch, (2) a plate with initial imperfections at different surface locations, and (3) a plate with a weaker skin layer. The peridynamic simulations closely replicate experimental fracture patterns in float glass, both with and without initial imperfections. While imperfection location significantly influences fracture patterns, its effect on strength is minimal. A weaker plate skin layer with decreased strength leads to a finer crack distribution.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109802"},"PeriodicalIF":4.4,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518171","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 friction block size on the tribological behavior of high-speed train brake interfaces in cold environments","authors":"Renxia Wang ,&nbsp;Zaiyu Xiang ,&nbsp;Qixiang Zhang ,&nbsp;Shaohao Deng ,&nbsp;Zhaolin Liu ,&nbsp;Jiliang Mo ,&nbsp;Zhongrong Zhou","doi":"10.1016/j.engfailanal.2025.109848","DOIUrl":"10.1016/j.engfailanal.2025.109848","url":null,"abstract":"<div><div>High-speed train braking systems operate in open environments, making their performance vulnerable to external conditions. Under extreme cold, the braking interface undergoes complex tribological behaviors that can drastically reduce braking efficiency and pose risks to operational safety. In conventional service environments, optimizing the dimensions of brake pad friction blocks is considered an effective method to improve the frictional performance characteristics of the braking interface, the effects of block size in extreme cold conditions remain insufficiently explored. To investigate this, we designed four blocks of varying sizes and employed a high-speed train braking simulation device to examine their influence on friction, wear, braking performance, and noise in an extremely cold environment (−40 °C). The results indicate that under such conditions, the size of the block significantly affects the braking interface in terms of friction and wear, braking, and noise. Specifically, the block with small size exhibited minimal eccentric wear, introduced fewer wear debris into the braking interface, had a smaller contact platform area, and generated lower-intensity, less fluctuating friction-induced vibration and noise (FIVN). As the diameter of the block increased, eccentric wear intensified, leading to a higher amount of wear debris entering the braking interface. Additionally, a larger block diameter resulted in an increased frictional contact area, generating more frictional heat. The accumulated wear debris compacted to form a larger contact platform, which led to high-intensity FIVN. Compared to the continuous FIVN produced by the with small size, the other three block sizes exhibited intermittent FIVN. Overall, block size significantly influences the tribological behavior of the high-speed train braking interface in extremely cold environments. Therefore, block size must be a key consideration in the design of brake pads for operation in extremely cold environments.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109848"},"PeriodicalIF":4.4,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144500918","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure analysis of in-service Type-II CNG cylinders from composite part damaged by hexagon flange bolt","authors":"Byoungil Jeon ,&nbsp;Changhyup Park","doi":"10.1016/j.engfailanal.2025.109842","DOIUrl":"10.1016/j.engfailanal.2025.109842","url":null,"abstract":"<div><div>This paper investigated the failure of in-service Type-II compressed natural gas (CNG) cylinders whose composite parts were damaged by contact with hexagon flange bolts, i.e., clamp bolts, in buses. Eighteen Type-II CNG cylinders that had been in service for 7–10 years were examined: mechanical tests and chemical analysis were conducted on 12 cylinders; extreme temperature cycling tests on 4 cylinders; ambient temperature cycling tests on 2 cylinders. The results showed that pre-existing damage of composite part increased in size under cyclic pressurization, and cylinders with severe composite defects eventually ruptured. These experiments confirmed that the interference from hexagon flange bolts, leading to damage of the composite part is a critical safety hazard. It is recommended that clamp attachment bolts should be redesigned or installed with sufficient clearance, e.g. a smaller-head hexagon bolt and a washer, to avoid contact with the cylinder, and that periodic re-inspections be mandated to detect composite damage before catastrophic failure occurs.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109842"},"PeriodicalIF":4.4,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144510842","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":"Influence of microstructural gradient on Charpy V-notch impact toughness variability in X65 pipeline girth weld","authors":"Tirdad Niknejad,&nbsp;Cheng Qian,&nbsp;James A. Gianetto,&nbsp;Jidong Kang","doi":"10.1016/j.engfailanal.2025.109841","DOIUrl":"10.1016/j.engfailanal.2025.109841","url":null,"abstract":"<div><div>This study investigates the ductile-to-brittle transition behaviour of weld metal in a multipass girth weld extracted from a North American CO₂ steel pipeline (X65 grade), with a focus on understanding the causes of scatter in Charpy V-notch (CVN) impact energy values, particularly between −60 °C and −25 °C. CVN specimens were tested between −80 °C and 25 °C, and selected samples underwent post-test characterization to correlate fracture behaviour with microstructural variation through the weld thickness. Fracture surfaces and microstructures along the notch front and fracture edges were examined using optical microscopy, scanning electron microscopy, and electron backscattered diffraction. The results showed that the observed scatter in toughness data was primarily due to variations in the extent of the coarse columnar ferritic structure zone intersecting the CVN notch front. This microstructure, predominantly found in the weld cap and outer fill passes, was associated with lower impact toughness. A low density of high-angle grain boundaries (HAGBs) in these regions reduced resistance to crack propagation, contributing to the formation of large cleavage facets. The alignment of {001} cleavage planes with fracture edges and the presence of microcracks further highlighted the role of crystallography in fracture behaviour. Conversely, zones with finer equiaxed grains, present in the initial fill passes and characterized by a high density of HAGBs, exhibited enhanced plasticity and absorbed higher energy. The proposed integrated approach provides a microstructure-sensitive framework for interpreting scatter in weld metal toughness, supporting improved structural integrity assessments for pipeline welds.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109841"},"PeriodicalIF":4.4,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144548447","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure analysis of hook type grasping friction pair for automatic friction welding type strapping","authors":"Lei Geng ,&nbsp;Yue Yu ,&nbsp;Jianming Zhai ,&nbsp;Jiaqi Liu ,&nbsp;Jiahao Jin ,&nbsp;Qingkun He ,&nbsp;Jinquan Sun","doi":"10.1016/j.engfailanal.2025.109846","DOIUrl":"10.1016/j.engfailanal.2025.109846","url":null,"abstract":"<div><div>Automatic friction welding type strapping machine is widely used for packing in industry, which can form solder welding joints of metal or polymer bundling strips by reciprocating high-frequency vibration friction. The hook type grasping friction pair (HTG friction pair) is one of the important vulnerable components, and its service life ranges from 16 million to 24 million vibrations at a vibration frequency of 400 times per second. The HTG friction pair of cold working die steel (SKD11) only lasted for 8 million vibrations before failing due to fracture, falls short of the required service life of 16 million to 24 million vibrations. Composition analysis, microstructure and fracture morphology characterization, and performance evaluation were conducted on the failed samples. The research results indicate that the HTG friction pair experienced multi-source high-cycle fatigue fracture at the chamfer radius and the hook groove, which is mainly because the chamfer radius is too small, and the hook grooves left on the surface by wire electrical discharge machining (WEDM) form stress concentration sources. Secondly, the forging ratio is insufficient, and the presence of eutectic carbide further accelerates the propagation of cracks. The optimization measures to improve the service life of HTG friction pair have been proposed.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109846"},"PeriodicalIF":4.4,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518166","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":"Fragility analysis of RC columns confined with CFRP grid-reinforced ECC under vehicle collisions","authors":"Wei Wang ,&nbsp;Jiahui Fu ,&nbsp;Zhichen Fang ,&nbsp;Shuai Wang ,&nbsp;Rongxin Zhou","doi":"10.1016/j.engfailanal.2025.109798","DOIUrl":"10.1016/j.engfailanal.2025.109798","url":null,"abstract":"<div><div>Bridge piers and building columns are susceptible to impact loading, particularly from vehicle collisions, posing a significant threat to public safety. Carbon fiber reinforced polymer (CFRP) grid-reinforced engineering cementitious composite (ECC) is a promising material for enhancing the resistance of regular reinforced concrete (RC) columns. This study numerically investigates the dynamic performance of RC columns confined with CFRP grid-reinforced ECC under vehicle collision and compares them with standard RC columns. The numerical results indicate that the strengthening method can significantly reduce displacement during the collision process, while the impact forces on the two types of columns are very similar. Additionally, the ECC material demonstrates strong energy dissipation capacity. To evaluate the anti-collision performance of the columns, the impact fragility of both types of columns is assessed using a surrogate model called Gaussian process regression, considering multiple variables. The augment uniform design sampling method is utilized to generate homogeneous samples, and fragility is derived based on Monte Carlo simulations. The fragility results show that for the same impact intensity, the failure probability of retrofitted columns is greatly reduced compared to regular RC columns. Finally, a global Sobol sensitivity analysis is conducted to identify the sensitive variables during collision.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"180 ","pages":"Article 109798"},"PeriodicalIF":4.4,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502096","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}