Engineering Failure Analysis最新文献

{"title":"Role of oxide scale on the localised corrosion of low carbon steel pipeline in cooling system","authors":"Yirong Yao ,&nbsp;Rongrong Jiang ,&nbsp;Yanping Wei ,&nbsp;Ming Li ,&nbsp;Liuyi Huang ,&nbsp;Huanming Lu ,&nbsp;Peiling Ke","doi":"10.1016/j.engfailanal.2024.108940","DOIUrl":"10.1016/j.engfailanal.2024.108940","url":null,"abstract":"<div><div>This study systematically investigated the corrosion behavior of the oxide scale on low carbon steel cooling water pipelines. The results showed that the oxide scale mainly consisted of Fe₃O₄ and dispersed precipitated Fe phase, exhibiting good electrical conductivity. The Volta potential of the internal Fe₃O₄ within the oxide scale was over 80 mV higher than that of both the precipitated Fe phase and the substrate. During service, complex galvanic corrosion couples were formed, leading to galvanic corrosion. The presence of the oxide scale had a significant negative impact on the corrosion resistance of the low carbon steel water pipes.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417916","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 hybrid failure analysis model design for marine engineering systems: A case study on alternative propulsion system","authors":"Kadir Cicek ,&nbsp;Seyid Mahmud Esad Demirci ,&nbsp;Dogan Sengul","doi":"10.1016/j.engfailanal.2024.108929","DOIUrl":"10.1016/j.engfailanal.2024.108929","url":null,"abstract":"<div><div>Marine engineering systems have a fundamental role in ensuring the efficiency, safety, and sustainability of maritime transportation. The performance and reliability of these systems, particularly propulsion systems, are of paramount importance. This paper introduces a pioneering hybrid failure analysis model that integrate the Variable Weighted Synthesis Analytic Hierarchy Process (VWS-AHP) with the conventional Failure Mode and Effect Analysis (FMEA) methodology. The primary objective is to enhance the comprehension of failure modes within marine engineering systems, particularly focusing on alternative propulsion systems. While conventional FMEA is a widely employed methodology for analysis of failure modes, its capacity and effectiveness can be further augmented by integrating complementary techniques. The proposed hybrid model combines the robustness of FMEA in identifying failure modes with the VWS-AHP method’s ability to handle complex decision-making scenarios involving multiple criteria and varying levels of importance. This integration affords a comprehensive framework to assess failure risks, prioritize critical failure pathways, and evaluate the potential impacts of failures in marine engineering systems. To demonstrate the applicability of the proposed model, we conduct a case study on an alternative propulsion system. The outcomes of the case study showcase the efficacy of the hybrid model in enhancing FMEA.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417917","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":"Relationship between tension and vertical vibration of roll system of twenty-high rolling mill","authors":"Xiangrong Wang ,&nbsp;Xiaoyan Xiong ,&nbsp;Congming Li ,&nbsp;Ming Wang ,&nbsp;Linkai Niu ,&nbsp;Bing Wu","doi":"10.1016/j.engfailanal.2024.108938","DOIUrl":"10.1016/j.engfailanal.2024.108938","url":null,"abstract":"<div><div>Abnormal vibration of the roll system seriously affects the quality of the rolled product and even the occurrence of strip breakage. There are many reasons for roll system vibration, such as roll damage, roll bearing failure, and fluctuations in rolling parameters. Especially for 20-roll high-precision ultra-thin strip mills, a key condition for strip rolling is to apply substantial inlet and outlet tension, with the impact of tension fluctuation increasing as the strip becomes thinner. In this paper, firstly, a dynamic rolling force model that accounts for tension fluctuations and vertical vibrations is established. Subsequently, a vertical vibration dynamics equation for the roll system of the twenty-high rolling mill was established. Then the rolling force model was substituted into the dynamics equation to investigate the relationship between tension fluctuations and roll system vibrations. The results indicate that: (1) Tension fluctuations can cause vibrations in the roll system. With the same fluctuation amplitude, the amplitude of the roller system vibration caused by the inlet tension can reach 10 times the amplitude of the roller system vibration caused by the outlet tension; (2) The vibration amplitude is affected by both the tension magnitude and the fluctuations amplitude and it is mainly influenced by the tension fluctuation when the tension magnitude changes are not significant; (3) Fluctuations in inlet and outlet tension will reduce the damping term and stiffness term, respectively, which increases the main resonance amplitude. Finally, the effectiveness of the model is verified by the experiment. The average inaccuracy between the simulated and measured vibration amplitudes is 13 %.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417922","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study of corrosion and failure mechanism of the galvanized steel pipes of meteorological tower serviced in the South China Sea","authors":"Haixian Liu ,&nbsp;Hongmei Gao ,&nbsp;Jiongming Chen ,&nbsp;Ruoling Liu ,&nbsp;Yi Zhang ,&nbsp;Yansheng Yin ,&nbsp;Hongfang Liu ,&nbsp;Shaojia Fan ,&nbsp;Hongwei Liu","doi":"10.1016/j.engfailanal.2024.108933","DOIUrl":"10.1016/j.engfailanal.2024.108933","url":null,"abstract":"<div><div>Corrosion issues of steel in the natural tropical marine atmospheric environment widely exist, and they can easily cause the failure of engineering equipment. However, the related studies are poor. Therefore, a deep analysis of the corrosion behavior and failure mechanism of steel materials in natural environments is urgent and important. In this work, the corrosion and failure mechanisms of galvanized steel pipes of a meteorological tower in the South China Sea were deeply studied. Results demonstrated that galvanized steel pipes at a low height happen a serious uniform and localized corrosion, while the bottom surface of each pipe facing the ground is severely corroded. The damage to the galvanized layer and the subsequent steel corrosion in high temperature and humidity conditions are mainly caused by bacteria and Cl⁻. Some bacteria with high corrosivity, such as <em>Desulfovibrionales</em>, <em>Seminibacterium</em>, <em>Acinetobacter</em>, <em>Ralstonia</em>, <em>Proteobacteria Streptococcus</em>, and <em>Lactobacillus</em>, are found beneath the rust layer, and they can significantly accelerate steel corrosion. The maximum localized corrosion rate is 0.20 mm/y.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417923","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 dynamic response and impact resistance of corrugated plate-reinforced concrete under simulated rockfall","authors":"Zhu Peilin ,&nbsp;Wang jinghe ,&nbsp;Yan Songhong ,&nbsp;Wang Junshun","doi":"10.1016/j.engfailanal.2024.108922","DOIUrl":"10.1016/j.engfailanal.2024.108922","url":null,"abstract":"<div><div>In this study, corrugated plate material is used as the internal mold for the reinforced concrete structure, proposing a combined shelter structure designed to protect against rockfall hazards in mountainous areas. The research focuses on the impact of low-velocity rockfall (below 150 km/h) directly hitting both the reinforced concrete structure and the corrugated plate and reinforced concrete combined shelter structure. The accuracy of the numerical simulation results is validated through comparative analysis with indoor model experiments. Further investigation reveals the impact resistance and failure characteristics of RC (Reinforced Concrete) structures, CPRC(D) (Corrugated plate double-layer reinforced concrete composite structure) structures and CPRC(S)（Corrugated plate single-layer reinforced concrete composite structure）, with the residual resistance index (RRI) introduced for the quantitative analysis of the residual load-bearing capacity of the protective structures post-impact. The results indicate that the shape of impact craters and the maximum impact force obtained through numerical simulations closely match the experimental findings, demonstrating the validity of the simulation parameters. Under the same impact energy, the maximum peak stress at various points in the CPRC structure is reduced by more than 50 % compared to the RC structure. Damage to the RC structure under rockfall impact is primarily characterized by central penetration failure and extensive development of diagonal cracks. In contrast, the CPRC structure effectively suppresses penetration, dent deformation, and crack propagation, significantly reducing the volume of concrete damage and the proportion of rebar damage, with the residual resistance index consistently remaining above 0.27.</div><div>The corrugated plate and reinforced concrete combined structure outperforms the reinforced concrete structure in several impact resistance factors, including maximum impact force, effective stress extremes, structural damage, and penetration depth. Additionally, after reinforcement with corrugated plates, the CPRC structure maintains a high level of impact resistance in most scenarios, even when the lower layer of rebar is eliminated, providing a theoretical basis and preliminary feasibility proof for the lightweight modification of the structure.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417918","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 atmospheric relief diaphragm in the low pressure steam turbine","authors":"Jeong-Min Lim ,&nbsp;Woo-Cheol Kim ,&nbsp;Jung-Gu Kim","doi":"10.1016/j.engfailanal.2024.108935","DOIUrl":"10.1016/j.engfailanal.2024.108935","url":null,"abstract":"<div><div>In this study, the causes of failure and prevention methods for the atmospheric relief diaphragm in a low-pressure steam turbine were evaluated. The atmospheric relief diaphragm is designed to vent and burst at its center when the pressure in the exhaust housing exceeds 0.7 barG due to steam. However, visual inspection revealed that failure occurred along the flange mounting, rather than at the center of the diaphragm. Fatigue failure was identified as the cause, based on SEM analysis. Internal pressure fluctuations in the turbine caused bending along the fixed edge of the diaphragm. To confirm the occurrence of fatigue failure, finite element analysis was performed using a maximum internal pressure of 0.023 barG and a frequency of 60 Hz. The maximum deformation was 18.8 mm, which is less than the distance between the diaphragm and the knife, 30 mm. However, the maximum stress was 23.7 MPa, which exceeded the fatigue strength of A1050, 15 MPa, with stress concentration at the diaphragm edge, confirming edge fatigue failure prior to central knife failure. To identify an alternative material, finite element analysis was conducted using higher fatigue strength than A1050 under the same conditions. While the maximum stress was similar to that of A1050, it was below the fatigue strength of the alternative materials. Consequently, to prevent unexpected failures, it is recommended to use materials with higher fatigue strength than A1050 to enhance fatigue life of the diaphragm.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417913","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":"Evaluating the ductile failure characteristics of CuZn30 brass under different stress conditions","authors":"Mehdi Ganjiani,&nbsp;Sina Ghobadi,&nbsp;Ghader Faraji","doi":"10.1016/j.engfailanal.2024.108932","DOIUrl":"10.1016/j.engfailanal.2024.108932","url":null,"abstract":"<div><div>The investigation of ductile failure in CuZn30 brass under various stress triaxialities and Lode angles is the main subject of this paper. To accomplish this, six different specimen geometries were fabricated, including dog-bone, notched, two types of in-plane shear, torsion, deep drawing, upsetting and central-hole specimens. Only dog-bone, notched, two shears specimens were tested in three orientations: rolling, diagonal, and transverse to explore potential anisotropic properties in plastic deformation. A fully coupled ductile damage-plasticity model, incorporating the effects of stress triaxiality and Lode angle, along with a non-linear damage evolution law, is used to predict material failure. The modified Ganjiani and Lou ductile failure models were employed as failure onset criteria. Despite variations in their mathematical formulations, both models were considered due to their comparable predictions. Experimental results were validated through a combination of experimental and numerical simulations using ABAQUS with VUSDFLD and VUHARD codes. The outcomes of the simulation demonstrated good concordance with the results obtained through experiment, particularly in terms of force and the softening (necking) zone for all specimen types. Both failure models produced nearly identical failure strain values and accurately predicted damage initiation locations. The fracture strains obtained from numerical simulations were also experimentally validated using images of the ruptured cross-sections, processed with Microstructural Image Processing (MIP) software. For the dog-bone, notched, shear-60°, torsion, and central-hole specimens, failure occurs at the maximum force, where the force–displacement curve’s slope reaches zero. However, for the shear-45°, deep-drawing, and upsetting specimens, failure is identified at the inflection point, where the curve changes from concave upward to concave downward.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417719","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 CFD investigation of fatigue damage of welded cantilever under high-speed train","authors":"Jianhui Jing ,&nbsp;Chengtao Li ,&nbsp;Zeyu Tao ,&nbsp;Yuanbin Zhang ,&nbsp;Zefeng Wen ,&nbsp;Chaotao Liu ,&nbsp;Shuanbao Yao","doi":"10.1016/j.engfailanal.2024.108926","DOIUrl":"10.1016/j.engfailanal.2024.108926","url":null,"abstract":"<div><div>This paper deals with the fatigue damage of the welded cantilever under a high-speed train subjected to wind-induced loading using a field test campaign and a CFD (Computational Fluid Dynamic) simulation. The results show that significant airflow pressure on the cantilever frames and the structural resonance are the main cause of the fatigue damage of welded joints. During long-term operation, the free end of the cantilever tends to vibrate undesirably, which affects the service life of the structure. Firstly, a finite element model with constant amplitude of wind pressure is created based on the current design specifications to assess the static and fatigue strength of the cantilever. The simulation results show that the structural strength meets the standard design requirements. However, the results of the field test show that the acceleration at the free end of the cantilever is 32.0 m/s², which far exceeds the relevant requirements. Meanwhile, there is a significant difference in aerodynamic pressure on the frame surfaces between the leading and trailing cars. An aerodynamic model is created for two full-size cars with the CFD method. The results show that FIV (flow-induced vibration) is the main cause of the continuous vibration of the elastic cantilever frame as long as the wake shedding occurs at a frequency close to the natural frequency of the frame. This study provides a reference for the aerodynamic fatigue design of the equipment mounted high-speed trains, especially for structures with low stiffness affected by open airflow.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442284","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":"System identification for structural condition assessment: Application to critical neoclassical monuments in Nepal","authors":"Dipendra Gautam ,&nbsp;Rabindra Adhikari ,&nbsp;Simon Olafsson ,&nbsp;Rajesh Rupakhety","doi":"10.1016/j.engfailanal.2024.108931","DOIUrl":"10.1016/j.engfailanal.2024.108931","url":null,"abstract":"<div><div>This paper presents structural condition assessment of some critical neoclassical monuments in Nepal using nonparametric and parametric system identification techniques. Neoclassical buildings in Nepal house critical administrative units. Structural condition assessment of such buildings is therefore important for the safety of their occupants and interrupted function during and after major earthquakes. The historical and cultural values of such monuments necessitate regular structural assessment for maintenance, repair, and preservation. Dynamic characteristics such as natural vibration frequencies of structures provide valuable insights on their structural condition. While numerical models are commonly used to estimate eigen frequencies of structures, they are associated with large uncertainties in massive monuments with complex structural and geometrical configurations. Noninvasive dynamic identification techniques provide an alternative means in such structures. Ambient vibration records from six neoclassical monuments in the Kathmandu Valley, Nepal are used in this study to estimate vibration frequencies of the structures in different states. The structures were damaged during the 2015 Gorkha earthquake, and subsequently retrofitted. Changes in vibration frequencies before and after retrofitting provide useful insights on structural improvement through retrofitting. Input-output and output-only system identification techniques are tested to simplify the structural condition assessment approach. We conclude that the state space system identification can stably quantify dynamic properties so stiffness variation can be confidently extracted, which is the key application for noninvasive structural system identification. Also, using minimum number of sensors, we captured damage aggravation deploying the modal assurance criterion. The outcomes indicate that structural condition assessment of complex structures is possible using a limited number of sensors for circumstances such as damage aggravation to temporal variation (evolution/reduction) of dynamic characteristics.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417722","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":"Hydrogen embrittlement effects on remaining life and fatigue crack growth rate in API 5L X52 steel pipelines under cyclic pressure loading","authors":"Omar Bouledroua ,&nbsp;Djamel Zelmati ,&nbsp;Zahreddine Hafsi ,&nbsp;Milos B. Djukic","doi":"10.1016/j.engfailanal.2024.108917","DOIUrl":"10.1016/j.engfailanal.2024.108917","url":null,"abstract":"<div><div>Transporting hydrogen gas through the existing natural gas pipeline network offers an efficient solution for energy storage and conveyance. Hydrogen generated from excess renewable electricity can be conveyed through the API 5L steel-made pipelines that already exist. In recent years, there has been a growing demand for the transportation of hydrogen through existing gas pipelines. Therefore, numerical and experimental tests are required to verify and ensure the mechanical integrity of the API 5L steel pipelines that will be used for pressurized hydrogen transportation. Internal pressure loading is likely to accelerate hydrogen diffusion through the internal pipe wall and consequently accentuate the hydrogen embrittlement of steel pipelines. Furthermore, pre-cracked pipelines are susceptible to quick failure mainly under a time-dependent cyclic pressure loading that drives fatigue crack propagation. Meanwhile, after several loading cycles, the initial cracks will propagate to a critical size. At this point, the remaining service life of the pipeline can be estimated, and inspection intervals can be determined. This paper focuses on the hydrogen embrittlement of API 5L steel-made pipeline under cyclic pressure loading. Pressurized hydrogen gas is transported through a network of pipelines where demands at consumption nodes vary periodically. The resulting pressure profile over time is considered a cyclic loading on the internal wall of a pre-cracked pipeline made of API 5L steel-grade material. Numerical modeling has allowed the prediction of fatigue crack evolution and estimation of the remaining service life of the pipeline. The developed methodology presented in this paper is based on the ASME B31.12 standard, which outlines the guidelines for hydrogen pipelines with reference to the ASME BPVC Section VIII, Division 3, Article KD-10.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":null,"pages":null},"PeriodicalIF":4.4,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142420528","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}