Engineering Failure Analysis最新文献

{"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}

{"title":"Experimental and simulation study on the microstructural evolution and fatigue life of 316L stainless steel under different periodic overload conditions","authors":"Haifeng Zhai ,&nbsp;Wei Jiang ,&nbsp;Yang Wang ,&nbsp;Yanzhao Yang ,&nbsp;Haiting Lv","doi":"10.1016/j.engfailanal.2025.109475","DOIUrl":"10.1016/j.engfailanal.2025.109475","url":null,"abstract":"<div><div>Accurate fatigue life prediction under periodic overload conditions is crucial for ensuring the reliability of engineering structures. This study investigates the low-cycle fatigue (LCF) behavior of 316L stainless steel under various overload conditions, considering key factors such as strain amplitude, consecutive overload cycles, load sequence, and cycle interval. The results indicate that their influence on fatigue life follows a descending order of significance. Notably, this study innovatively identifies that irregular overload intervals can induce an internal “training effect”, effectively delaying fatigue damage. Furthermore, an improved fatigue life prediction method tailored for overload conditions is proposed and validated through experimental results. These findings provide new insights into fatigue damage mechanisms under periodic overload conditions and offer valuable guidance for refining fatigue life prediction models and optimizing engineering design strategies.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109475"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561559","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":"Structural assessment and retrofitting of an old building in highly seismic zone of Pakistan","authors":"Obaidullah khan ,&nbsp;Muhammad Faisal Javed ,&nbsp;Sanaullah Khan","doi":"10.1016/j.engfailanal.2025.109478","DOIUrl":"10.1016/j.engfailanal.2025.109478","url":null,"abstract":"<div><div>This study evaluates the seismic performance of a 40-year-old, four-story reinforced concrete building in Abbottabad, Pakistan, a highly seismic region. The structure, designed without adherence to current seismic provisions outlined in the Building Code of Pakistan 2021, was analyzed using a displacement-based approach (nonlinear static analysis) and incremental dynamic analysis (nonlinear dynamic analysis). The static analysis revealed that the building met performance objectives but exhibited low base shear and stiffness in its longer (x) direction, leading to significant member-level damage. Dynamic analysis further highlighted excessive drift and displacement in the x-direction, attributed to the building’s stiff-weak configuration, with excessive stiffness in the shorter (y) direction to support gravity loads and insufficient strength in the x-direction. To mitigate these vulnerabilities, shear walls were analytically introduced in the x-direction, effectively controlling displacement and reducing damage. The findings underscore the need for retrofitting older structures to enhance seismic resilience in high-risk regions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109478"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579351","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 and guidelines for further exploitation of centrifugal slurry pumps used for copper flotation waste transport: A case study","authors":"Jakub Wróbel ,&nbsp;Damian Pietrusiak ,&nbsp;Radosław Rozmus ,&nbsp;Robert Roicki ,&nbsp;Bartłomiej Zarzycki ,&nbsp;Paweł Stefanek","doi":"10.1016/j.engfailanal.2025.109479","DOIUrl":"10.1016/j.engfailanal.2025.109479","url":null,"abstract":"<div><div>High power slurry pumps are the core element of copper flotation waste transport. Pump failure can lead to shutdowns of the flotation process and high financial losses. This paper is a case study of three high power, split case, rubber lined, closed impeller, tangential discharge slurry pump failures, where all failed pumps were located at the first stage of three different pumping sections. Analysis of the material strength of each pump housing showed a strong reduction in the ultimate tensile strength to 25 %, 39 % and 46 % of the specified min value of 241 MPa for ASTM A48 Class 35 Gray Iron Castings. Microstructure analysis showed numerous micro cracks formed along with casting defects such as cementite, phosphorus eutectic and porosities. Vibration analysis identified interference between pump stages that led to low frequency beat phenomena that consequently could cause cyclic load on the castings. Detailed FEM modeling of the pump housing assembly, including main bolted connections, indicated that tightening the pump housing bolts with the correct torque or operation at a nominal pressure of 0.69 MPa could cause the pump housing to fail due to strongly reduced material properties. Further investigation showed that the ASTM A48 Class 35 Gray Iron and cast stainless steel bodies A743 CA6NM did not show overload both when the housings are properly bolted together and when a 30 % overload is introduced on one of the fasteners, given the proper material properties.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109479"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579343","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":"Influence of concrete interfaces on the damage and pull-out behavior of 3D-printed concrete structures","authors":"Qamar Shahzad,&nbsp;Fangyuan Li","doi":"10.1016/j.engfailanal.2025.109470","DOIUrl":"10.1016/j.engfailanal.2025.109470","url":null,"abstract":"<div><div>This research examines the pull-out behavior of steel reinforcement bars embedded within 3D-printed concrete (3DPC) specimens. A finite element model (FEM) incorporating cohesive elements was developed and validated through experimental data to assess the impact of printed concrete-to-concrete interfaces on the pull-out behavior of 3DPC. A detailed analysis of the interfaces’ influence on the 3D printed specimens revealed the peak load and slip behavior, failure mechanisms, and damage criteria. Additionally, a thorough investigation was conducted on how interfacial bond strength, layer and strip dimensions, print angle, and effective length of bond impact on pull-out behavior of 3DPC. The results reveal that 3DPC demonstrates reduced initial stiffness compared to cast specimens, maintaining consistent stiffness in both the X and Y directions. The mold-cast specimen demonstrates a 9.38 % higher load-bearing capacity than the interlayer 3D printed specimen and a 25 % higher load-bearing capacity than the interstrip 3D printed specimen. The percentage difference between the experimental and simulated results for these specimens is less than 5 %, indicating good agreement. The study shows that the peak load changes with the print angle, initially decreasing from 0° to 30° and then rising from 30° to 90°, with the maximum load occurring at 90°. Specimens printed at a 30° angle exhibit the highest damage due to increased stress concentrations, while those printed at 90° experience lowest damage because of more effective stress distribution. Additionally, increasing the layer size significantly enhances peak load capacity, with larger layers improving load distribution and structural support. Ultimately, specimens with a 50 mm bond length demonstrate the highest peak load and the lowest slip, indicating superior load-bearing capacity and bond performance. In contrast, shorter bond lengths result in lower peak loads and greater slip values. In conclusion, this study provides a foundation for future research on 3DPC modeling, particularly regarding concrete interfaces.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109470"},"PeriodicalIF":4.4,"publicationDate":"2025-03-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552222","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":"Microstructural effect on fracture evolution in spheroidal graphite iron: Numerical analysis","authors":"Xingling Luo ,&nbsp;Tito Andriollo ,&nbsp;Konstantinos P. Baxevanakis ,&nbsp;Vadim V. Silberschmidt","doi":"10.1016/j.engfailanal.2025.109459","DOIUrl":"10.1016/j.engfailanal.2025.109459","url":null,"abstract":"<div><div>Spheroidal graphite iron (SGI) has found extensive application across various engineering sectors thanks to its excellent combination of mechanical properties at elevated temperatures and durability. The morphology of graphite inclusions in SGI has a great effect on its mechanical properties in tension. Despite extensive research, the influence of its microstructure on the fracture behaviour has not been fully investigated. In contrast to previous studies of fracture behaviour, the present work attempts to investigate the relation between graphite morphology and fracture behaviour of SGI by using 2D images (slices) from X-ray tomography (X-CT). In this study, a novel approach based on microstructural simulations is proposed. SGI slices were obtained from X-CT and every fifth image was selected to ensure a balanced representation of the microstructure that neither completely alters the character of the distribution of graphite particles nor significantly changes the fraction of any specific graphite particle. The crack path generated in representative volume elements (RVEs) is used to investigate the effect of graphite particles and depict the crack thickness in 3D. The tensile properties and damage mechanism of finite-element methods are validated from experiments. It was found that large and irregular graphite particles accelerated the crack-initiation process. Besides, the spacing between graphite particles should be as large as possible to enhance the material’s fracture toughness. This research provides an effective way to find optimum arrangements of graphite particles or voids for the design of structural components with increased fracture toughness. The application of micromechanics modelling has the potential to provide new insights useful for the design and manufacture of metal-matrix composites.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109459"},"PeriodicalIF":4.4,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611335","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":"Fragility analysis of wind turbine towers under combined wind and seismic loads considering wind-induced fatigue","authors":"Jia-Xiang Li ,&nbsp;Ling-Peng Wang ,&nbsp;Zhuo-Qun Zhang ,&nbsp;Chao Zhang ,&nbsp;Zhi-Qian Dong","doi":"10.1016/j.engfailanal.2025.109472","DOIUrl":"10.1016/j.engfailanal.2025.109472","url":null,"abstract":"<div><div>Wind-induced fatigue damage, which is a crucial factor affecting the lifespan of wind turbine towers, is frequently overlooked in fragility analysis of wind turbine towers. Moreover, the effect of bolt slippage on the mechanical properties of lattice-type wind turbine towers is significant, warranting an investigation into its influence on fatigue damage. This paper establishes a wind-seismic fragility analysis framework for wind turbine towers that incorporates wind-induced fatigue damage calculations. First, historical data on the wind speed and wind direction are collected, and a joint probability model of the wind speed and direction is established by the copula function on the basis of the historical data. The wind-induced fatigue damage of the wind turbine tower is then calculated according to this probability model. Subsequently, in the fragility analysis, the structural performance is adjusted according to the results of the fatigue damage calculations, followed by static pushover analysis and dynamic time-history analysis. Ultimately, fragility surfaces and curves are established. To illustrate the application of the framework, a wind turbine tower is selected as a case study, and bolt slippage is considered in the analysis. Comparative analysis is employed to investigate the impact of bolt slippage on the fatigue damage of wind turbine towers. The results reveal that wind fatigue damage significantly affects the fragility of wind turbine towers under combined wind and earthquake loads. Furthermore, the bolt slippage effect exacerbates fatigue damage to wind turbine towers.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109472"},"PeriodicalIF":4.4,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552218","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 a premature failure axle from a road-rail truck under rotary bending fatigue","authors":"Pedro R. da Costa ,&nbsp;V. Infante ,&nbsp;M. Freitas","doi":"10.1016/j.engfailanal.2025.109464","DOIUrl":"10.1016/j.engfailanal.2025.109464","url":null,"abstract":"<div><div>The present study provides a detailed analysis of an axle from a road-rail truck. The main objective of this work was to characterize a premature axle fracture failure in the context of ongoing derailment investigations. A comprehensive material and macro/micro analysis of the axle fracture was conducted which revealed that the premature failure resulted from rotary bending fatigue. The fatigue fracture occurred specifically in the braking system attachment zone. Microscopy and SEM analysis demonstrated that initiation occurred on the surface of the axle. A combination of critical factors resulted in imposing stress below the fatigue strength and leading to a premature failure of the axle. The determined critical factors were fretting damage, stress induced by tightening, and rotary bending. Through the combination of all identified influential variables, multiple crack initiation sites were detected across the braking system press-fitted regions. Following the forensic examination, a plan was proposed outlining the necessary actions, checks, and tests necessary to correct the existing failure through maintenance and/or establishing the time intervals between axle inspections. Corrective actions were recommended regarding the assembly and regular inspection of the braking system, focusing on the contact pressure region with the axle. The routine inspection should include a thorough examination of the fretting affected region for potential cracks and uneven damage utilizing visual amplifying means and ultrasonic testing.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"173 ","pages":"Article 109464"},"PeriodicalIF":4.4,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520873","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure analysis of weld cracking in wax oil cracking unit","authors":"Hongbin Xie ,&nbsp;Xianrui Zou ,&nbsp;Fangfang Zhang ,&nbsp;Xianjing Lu ,&nbsp;Fang Zhang ,&nbsp;Liuyi Huang ,&nbsp;Fengping Zhong ,&nbsp;Mao Cheng ,&nbsp;Xuebin Wang ,&nbsp;Jiabin Liu ,&nbsp;Guoping Ling","doi":"10.1016/j.engfailanal.2025.109467","DOIUrl":"10.1016/j.engfailanal.2025.109467","url":null,"abstract":"<div><div>Pressure piping systems are a crucial component in chemical plants. However, pressure piping and its accessories in chemical plants are exposed to complex service environments, and defects in piping materials and welding further increase the risk of failure. This study analyzes the cracking failure of a drain valve in a paraffin oil cracking unit of a petrochemical enterprise. The location of the crack is the weld between the guide valve and the branch pipe, which is a full-penetration butt joint, employing a welding process of GTAW for the root pass and SMAW for the cover passes. Inspection and analysis revealed that stress concentration caused by defects on the inner wall of the valve, combined with sulfide corrosion in the medium, were the reasons for crack initiation. The cracks propagated under variable loads, and porosity defects in the weld seam and heat-affected zone accelerated the crack propagation rate, ultimately leading to corrosion fatigue failure of the valve. After analyzing the failure mechanism and process, we propose improvement suggestions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109467"},"PeriodicalIF":4.4,"publicationDate":"2025-02-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552217","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":"An Explainable AI approach for detecting failures in air pressure systems","authors":"Shawqi Mohammed Farea,&nbsp;Mehmet Emin Mumcuoglu,&nbsp;Mustafa Unel","doi":"10.1016/j.engfailanal.2025.109441","DOIUrl":"10.1016/j.engfailanal.2025.109441","url":null,"abstract":"<div><div>The Air Pressure System (APS) plays a crucial role in heavy-duty vehicles (HDVs), supplying pressurized air to essential subsystems such as braking and suspension. APS failures normally lead to vehicles being stranded on the road with associated safety and financial risks. Although detecting these failures is essential to prevent such events, the detection trustworthiness is equally important given the high sensitivity of this issue. This paper addresses the problem of APS failure detection using Explainable Boosting Machine (EBM), a highly intelligible and interpretable glass-box model. A dataset of operational driving data from 110 healthy vehicles, without any APS failures, and 30 faulty vehicles, with detected APS failures, was collected. First, essential preprocessing steps were developed to deal with the hierarchical big data and to extract indicative features. The main objective of EBM is to distinguish faulty vehicles from healthy ones based on those features while providing explanations for its decisions. The model succeeded in detecting most of the faulty vehicles with a small proportion of false alarms (roughly 5%); the overall accuracy was 91.4% and the F1 score was 0.80. In addition, the provided explanations were thoroughly investigated to evaluate the validity and trustworthiness of the model decisions. At the same time, the explanations themselves were assessed based on domain knowledge to prove their efficacy and relevance. When compared with a human expert analysis, these explanations highly align with the experts’ knowledge of the APS problem. The proposed methodology is easily adaptable for other time-series predictive maintenance applications across different fields.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"173 ","pages":"Article 109441"},"PeriodicalIF":4.4,"publicationDate":"2025-02-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520876","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}