Engineering Failure Analysis最新文献

Enhanced static and fatigue performance of FDM 3D-printed polycarbonate adhesive joints using bio-inspired surface textures

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-21 DOI: 10.1016/j.engfailanal.2025.109626

Nidhal Naat , Yasmina Boutar , Sami Naïmi , Salah Mezlini , Alireza Akhavan-Safar , Ricardo .J.C. Carbas , Lucas F.M. da Silva

The bonding potential of additively manufactured polycarbonate (PC) material is still a relatively unexplored area, and the addition of bio-inspired surface texture to enhance adhesion, particularly concerning fatigue performance, has not yet been investigated. This study examines the effects of bio-surface texture on the static and fatigue strength of 3D-printed PC adhesive joints. The methodology involved firstly designing and 3D-printing substrates with as-printed and textured surfaces, inspired by the Tree Frog toe pads (TF) and Fish Scales (FS) surfaces. Subsequently, static and fatigue tensile tests were performed using Arcan joints, while the block shear method was adopted for the fatigue shear tests. The findings indicated that TF and FS textures significantly enhanced static tensile strength and extended both tensile and shear fatigue life by promoting mechanical interlocking and increasing the effective contact area, compared to the as-printed texture. Specifically, the TF and FS textures increased the static tensile strength by 51% and 31%, respectively. Under constant maximum fatigue loading conditions, TF and FS textures extended tensile fatigue life by 266 and 173 times, and shear fatigue life by 134 and 65 times. Moreover, adhesive joints with bio-inspired surfaces exhibit greater resistance than bulk adherends due to the increased sensitivity of 3D-printed adherends to defects, particularly voids, under cyclic loading. Therefore, to improve the static and fatigue resistance of 3D-printed PC adhesive joints, it is advisable to apply the load perpendicularly to the parts’ build orientation, design joints to withstand shear loads and include TF bio-texture on adherend surfaces.

{"title":"Enhanced static and fatigue performance of FDM 3D-printed polycarbonate adhesive joints using bio-inspired surface textures","authors":"Nidhal Naat , Yasmina Boutar , Sami Naïmi , Salah Mezlini , Alireza Akhavan-Safar , Ricardo .J.C. Carbas , Lucas F.M. da Silva","doi":"10.1016/j.engfailanal.2025.109626","DOIUrl":"10.1016/j.engfailanal.2025.109626","url":null,"abstract":"<div><div>The bonding potential of additively manufactured polycarbonate (PC) material is still a relatively unexplored area, and the addition of bio-inspired surface texture to enhance adhesion, particularly concerning fatigue performance, has not yet been investigated. This study examines the effects of bio-surface texture on the static and fatigue strength of 3D-printed PC adhesive joints. The methodology involved firstly designing and 3D-printing substrates with as-printed and textured surfaces, inspired by the Tree Frog toe pads (TF) and Fish Scales (FS) surfaces. Subsequently, static and fatigue tensile tests were performed using Arcan joints, while the block shear method was adopted for the fatigue shear tests. The findings indicated that TF and FS textures significantly enhanced static tensile strength and extended both tensile and shear fatigue life by promoting mechanical interlocking and increasing the effective contact area, compared to the as-printed texture. Specifically, the TF and FS textures increased the static tensile strength by 51% and 31%, respectively. Under constant maximum fatigue loading conditions, TF and FS textures extended tensile fatigue life by 266 and 173 times, and shear fatigue life by 134 and 65 times. Moreover, adhesive joints with bio-inspired surfaces exhibit greater resistance than bulk adherends due to the increased sensitivity of 3D-printed adherends to defects, particularly voids, under cyclic loading. Therefore, to improve the static and fatigue resistance of 3D-printed PC adhesive joints, it is advisable to apply the load perpendicularly to the parts’ build orientation, design joints to withstand shear loads and include TF bio-texture on adherend surfaces.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109626"},"PeriodicalIF":4.4,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860378","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}

引用次数: 0

Experimental and numerical investigation on inclined shear behaviour of steel fibre-reinforced cement grout

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-20 DOI: 10.1016/j.engfailanal.2025.109623

Jianhang Chen , Shiji Wang , Songsong Hu , Kun Wang , Banquan Zeng , Shaokang Wu , Wenbing Fan , Zhixiang Song , Xiaohang Wan

Experimental and numerical investigation were conducted on shear behaviour of steel fibre-reinforced cement grout (SFRCG) through inclined shearing. First, the influence of fibre volume fraction and tilt angle on shear characteristics of SFRCG was studied through inclined shear tests. Results indicate that adding steel fibres enhanced shear strength and ductility of cement grout. With fibre volume fraction increasing from 0 to 1.5%, shear strength of SFRCG initially increased and then decreased. It remained higher than plain grout. However, as tilt angle increased from 38° to 60°, shear strength of SFRCG continued to decrease. Steel fibres prevented cracks from penetrating. Consequently, specimens were not completely cut off. Moreover, adding steel fibres changed failure modes when tilt angle was 45°. Then, the scanning electron microscope (SEM) method was adopted to examine microstructure of SFRCG. Finally, parameter calibration was conducted based on a series of laboratory test results. Three-dimensional discrete element method (DEM) models of SFRCG were established. Shear failure process and mechanism of SFRCG were revealed based on the relationship between stress state and specimen microcrack evolution in DEM simulation. Numerical simulation results agreed well with laboratory test results. Additionally, function mechanism of steel fibres in cement-based materials was also discussed according to experimental and numerical results.

{"title":"Experimental and numerical investigation on inclined shear behaviour of steel fibre-reinforced cement grout","authors":"Jianhang Chen , Shiji Wang , Songsong Hu , Kun Wang , Banquan Zeng , Shaokang Wu , Wenbing Fan , Zhixiang Song , Xiaohang Wan","doi":"10.1016/j.engfailanal.2025.109623","DOIUrl":"10.1016/j.engfailanal.2025.109623","url":null,"abstract":"<div><div>Experimental and numerical investigation were conducted on shear behaviour of steel fibre-reinforced cement grout (SFRCG) through inclined shearing. First, the influence of fibre volume fraction and tilt angle on shear characteristics of SFRCG was studied through inclined shear tests. Results indicate that adding steel fibres enhanced shear strength and ductility of cement grout. With fibre volume fraction increasing from 0 to 1.5%, shear strength of SFRCG initially increased and then decreased. It remained higher than plain grout. However, as tilt angle increased from 38° to 60°, shear strength of SFRCG continued to decrease. Steel fibres prevented cracks from penetrating. Consequently, specimens were not completely cut off. Moreover, adding steel fibres changed failure modes when tilt angle was 45°. Then, the scanning electron microscope (SEM) method was adopted to examine microstructure of SFRCG. Finally, parameter calibration was conducted based on a series of laboratory test results. Three-dimensional discrete element method (DEM) models of SFRCG were established. Shear failure process and mechanism of SFRCG were revealed based on the relationship between stress state and specimen microcrack evolution in DEM simulation. Numerical simulation results agreed well with laboratory test results. Additionally, function mechanism of steel fibres in cement-based materials was also discussed according to experimental and numerical results.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109623"},"PeriodicalIF":4.4,"publicationDate":"2025-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143869318","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}

引用次数: 0

Dynamic behavior and safety assessment of vertical fall-arrest system with flexible tracks for transmission tower under falling impact load

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-20 DOI: 10.1016/j.engfailanal.2025.109608

Chongkai Fan , Dachang Zhang , Dabo Xie , Yi An , Fenghua Huang

This paper focuses on the dynamic behavior and safety assessment of vertical fall-arrest system with flexible tracks for transmission tower under falling impact load. Thirty drop tests were conducted using different test methods with different falling heights and hanging-board thicknesses. The dynamic behavior of the fall-arrest process was primarily researched, and the force–time curves of the flexible track and rope were obtained by tests. Furthermore, the strain of the hanging board and the rope grab during the fall were investigated, and energy dissipation and safety assessments were carried out. Finally, an energy balance calculation method based on the dynamic nonlinear stiffness of the rope was proposed to calculate the fall displacement and maximum impact load of the works. The results showed that the vertical fall-arrest system could extend the load-bearing time of workers through the deformation of the track and rope grab, thereby reducing the maximum impact force on them. However, vertical fall-arrest systems still pose safety risks, and the impact loads on workers often exceed the safety limits. The effect of the impact load on the material stiffness cannot be ignored, and it is unreliable to only conduct static analysis to predict the impact force and displacement of workers. The proposed energy balance calculation method based on the dynamic nonlinear stiffness has good accuracy. The research results can provide a reference for the dynamic behavior calculation and design of fall-arrest systems to further reduce the occurrence of falling accidents and for the construction and maintenance of transmission towers.

{"title":"Dynamic behavior and safety assessment of vertical fall-arrest system with flexible tracks for transmission tower under falling impact load","authors":"Chongkai Fan , Dachang Zhang , Dabo Xie , Yi An , Fenghua Huang","doi":"10.1016/j.engfailanal.2025.109608","DOIUrl":"10.1016/j.engfailanal.2025.109608","url":null,"abstract":"<div><div>This paper focuses on the dynamic behavior and safety assessment of vertical fall-arrest system with flexible tracks for transmission tower under falling impact load. Thirty drop tests were conducted using different test methods with different falling heights and hanging-board thicknesses. The dynamic behavior of the fall-arrest process was primarily researched, and the force–time curves of the flexible track and rope were obtained by tests. Furthermore, the strain of the hanging board and the rope grab during the fall were investigated, and energy dissipation and safety assessments were carried out. Finally, an energy balance calculation method based on the dynamic nonlinear stiffness of the rope was proposed to calculate the fall displacement and maximum impact load of the works. The results showed that the vertical fall-arrest system could extend the load-bearing time of workers through the deformation of the track and rope grab, thereby reducing the maximum impact force on them. However, vertical fall-arrest systems still pose safety risks, and the impact loads on workers often exceed the safety limits. The effect of the impact load on the material stiffness cannot be ignored, and it is unreliable to only conduct static analysis to predict the impact force and displacement of workers. The proposed energy balance calculation method based on the dynamic nonlinear stiffness has good accuracy. The research results can provide a reference for the dynamic behavior calculation and design of fall-arrest systems to further reduce the occurrence of falling accidents and for the construction and maintenance of transmission towers.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109608"},"PeriodicalIF":4.4,"publicationDate":"2025-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860425","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}

引用次数: 0

Discerning the degradation and failure mechanism of T91 grade reheater tube through integrated experimental and simulation approach

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-19 DOI: 10.1016/j.engfailanal.2025.109621

Avanish Kumar Chandan , Biraj Kumar Sahoo , Arpit Garg , Lalit Kumar Meena , Gaurav Kumar Bansal , Parikshit Munda , M. Ghosh

The reheater tube is a critical component of boiler in thermal power plants. The component contributes in determining the efficiency of the plant by regulating the temperature of steam entering low pressure turbine. In the present investigation, the reheater tube experienced operational failure after 60,000 h of service in a coal-based thermal power plant. The component was made with 9Cr-1Mo T91 grade of steel. The investigation encompassed bulk composition analysis, microstructure examination, mechanical property evaluation, fracture surface analysis, and thermodynamic- kinetic simulations. Composition and tensile strength of the alloy confirmed, that the component met the specified standards. The microstructural analysis revealed the presence of excessively coarse precipitates (up to ∼ 4 µm). Multi-layered scale formation was observed on both the inner and outer walls of the tube. Discontinuities at the interfaces between the scale, and the virgin alloy disrupted heat transfer between the fire-side outer wall, and the steam flowing through the reheater tube. Localized heat accumulation instigated overheating, and subsequent microstructural degradation of the component. The signature of structural change was endorsed by the coarsening of M₂₃C₆ precipitates and thick scale formation. The appearance of high density of creep voids along the grain boundaries suggested high temperature exposure for considerable time. Various theoretical approaches viz. Larson–Miller parametric approach and thermodynamic and kinetic simulations were used to estimate the operational temperature. Correlation of the predicted data with experimental findings indicated a temperature rise of up to 800 °C, which was beyond the recommended service temperature of the component. Long-term overheating degraded the mechanical properties of the alloy and the component ultimately failed pre-maturely during service.

{"title":"Discerning the degradation and failure mechanism of T91 grade reheater tube through integrated experimental and simulation approach","authors":"Avanish Kumar Chandan , Biraj Kumar Sahoo , Arpit Garg , Lalit Kumar Meena , Gaurav Kumar Bansal , Parikshit Munda , M. Ghosh","doi":"10.1016/j.engfailanal.2025.109621","DOIUrl":"10.1016/j.engfailanal.2025.109621","url":null,"abstract":"<div><div>The reheater tube is a critical component of boiler in thermal power plants. The component contributes in determining the efficiency of the plant by regulating the temperature of steam entering low pressure turbine. In the present investigation, the reheater tube experienced operational failure after 60,000 h of service in a coal-based thermal power plant. The component was made with 9Cr-1Mo T91 grade of steel. The investigation encompassed bulk composition analysis, microstructure examination, mechanical property evaluation, fracture surface analysis, and thermodynamic- kinetic simulations. Composition and tensile strength of the alloy confirmed, that the component met the specified standards. The microstructural analysis revealed the presence of excessively coarse precipitates (up to ∼ 4 µm). Multi-layered scale formation was observed on both the inner and outer walls of the tube. Discontinuities at the interfaces between the scale, and the virgin alloy disrupted heat transfer between the fire-side outer wall, and the steam flowing through the reheater tube. Localized heat accumulation instigated overheating, and subsequent microstructural degradation of the component. The signature of structural change was endorsed by the coarsening of M<sub>23</sub>C<sub>6</sub> precipitates and thick scale formation. The appearance of high density of creep voids along the grain boundaries suggested high temperature exposure for considerable time. Various theoretical approaches viz. Larson–Miller parametric approach and thermodynamic and kinetic simulations were used to estimate the operational temperature. Correlation of the predicted data with experimental findings indicated a temperature rise of up to 800 °C, which was beyond the recommended service temperature of the component. Long-term overheating degraded the mechanical properties of the alloy and the component ultimately failed pre-maturely during service.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109621"},"PeriodicalIF":4.4,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143856084","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}

引用次数: 0

Numerical optimization of conformal cooling channels for thermal distribution and stress characterization in additively manufactured high pressure die casting die

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-19 DOI: 10.1016/j.engfailanal.2025.109620

Xin He , Xiaoming Wang , Corey Vian , Miad Faezipour

The durability and efficiency of High Pressure Die Casting (HPDC) dies, particularly those with Conformal Cooling Channels (CCC) fabricated via Laser Powder Bed Fusion (LPBF), are essential for enhancing operational performance. The impact of the shape and location of CCC on the die insert performance has emerged as a significant issue, affecting die reliability. Using Computational Fluid Dynamics (CFD) simulations, this study developed a predictive model that effectively identified regions susceptible to conformal cooling effects, demonstrating the impact of CCC on temperature distribution, thermal stress concentration, water vaporization, and crack failure, closely aligning with observed conditions. Vapor generation was observed at CCC bends due to flow separation caused by abrupt changes in flow direction and velocity. The corrosion grooves act as initiation points for crack formation on the CCC wall. Pores formed along molten pool boundaries during LPBF. Three alternative CCC geometries—(a) increased-diameter CCC, (b) single-directional spiral CCC, and (c) bi-directional half pitch spiral CCC—were analyzed. The increased-diameter CCC improved cooling efficiency but exhibited greater thermal gradients and stress. Compared to the original single loop CCC, the spiral CCC design enhanced cooling performance due to its closer distance to the die insert surface and higher surface area. These improvements resulted in smaller thermal gradients and more uniform stress distribution for the spiral CCC. Failure life analysis revealed that spiral CCC geometries, especially bi-directional spirals, minimized Von-Mises and tensile stress, reduced vapor formation and improved structural integrity.

{"title":"Numerical optimization of conformal cooling channels for thermal distribution and stress characterization in additively manufactured high pressure die casting die","authors":"Xin He , Xiaoming Wang , Corey Vian , Miad Faezipour","doi":"10.1016/j.engfailanal.2025.109620","DOIUrl":"10.1016/j.engfailanal.2025.109620","url":null,"abstract":"<div><div>The durability and efficiency of High Pressure Die Casting (HPDC) dies, particularly those with Conformal Cooling Channels (CCC) fabricated via Laser Powder Bed Fusion (LPBF), are essential for enhancing operational performance. The impact of the shape and location of CCC on the die insert performance has emerged as a significant issue, affecting die reliability. Using Computational Fluid Dynamics (CFD) simulations, this study developed a predictive model that effectively identified regions susceptible to conformal cooling effects, demonstrating the impact of CCC on temperature distribution, thermal stress concentration, water vaporization, and crack failure, closely aligning with observed conditions. Vapor generation was observed at CCC bends due to flow separation caused by abrupt changes in flow direction and velocity. The corrosion grooves act as initiation points for crack formation on the CCC wall. Pores formed along molten pool boundaries during LPBF. Three alternative CCC geometries—(a) increased-diameter CCC, (b) single-directional spiral CCC, and (c) bi-directional half pitch spiral CCC—were analyzed. The increased-diameter CCC improved cooling efficiency but exhibited greater thermal gradients and stress. Compared to the original single loop CCC, the spiral CCC design enhanced cooling performance due to its closer distance to the die insert surface and higher surface area. These improvements resulted in smaller thermal gradients and more uniform stress distribution for the spiral CCC. Failure life analysis revealed that spiral CCC geometries, especially bi-directional spirals, minimized Von-Mises and tensile stress, reduced vapor formation and improved structural integrity.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109620"},"PeriodicalIF":4.4,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143863431","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}

引用次数: 0

Mitigating thermal cycling-induced failures in SiC-based hybrid IGBT modules: optimization of solder and reliability enhancements

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-19 DOI: 10.1016/j.engfailanal.2025.109619

Peisheng Liu , Yaohui Deng , Pengpeng Xu , Zhao Zhang , Jiajie Jin , Xiangdong Luo

The thermal–mechanical reliability of SiC-based hybrid IGBT modules is crucial for ensuring the long-term stability of high-power electronic systems, particularly under cyclic thermal stress. While prior research has extensively investigated traditional solder materials and individual reliability factors, these studies often lack comprehensive optimization strategies. To address this gap, the present study systematically enhances module reliability by combining finite element analysis (FEA) with the Taguchi optimization method. The focus is on enhancing the durability of solder interconnects under severe thermal cycling conditions, ranging from −40 °C to 125 °C. This work is novel in integrating nano-silver solder evaluation and optimization of Direct Bonded Copper (DBC) liner materials within a structured optimization framework, which significantly differentiates from previous studies. The results indicate that von Mises stresses are concentrated at the chip solder edges, reaching up to 157 MPa, which exceeds the yield strength and accelerates fatigue. The fatigue life predictions based on Engelmaier’s modified Coffin-Manson model show that nano-silver solder extends the module’s lifespan by approximately 90 % compared to conventional SAC305 solder. Additionally, the optimization results suggest that Si₃N₄ liners effectively reduce peak stress. These insights provide guidelines for designing highly durable SiC-based IGBT modules applicable to electric vehicles, renewable energy systems, and high-power converters.

{"title":"Mitigating thermal cycling-induced failures in SiC-based hybrid IGBT modules: optimization of solder and reliability enhancements","authors":"Peisheng Liu , Yaohui Deng , Pengpeng Xu , Zhao Zhang , Jiajie Jin , Xiangdong Luo","doi":"10.1016/j.engfailanal.2025.109619","DOIUrl":"10.1016/j.engfailanal.2025.109619","url":null,"abstract":"<div><div>The thermal–mechanical reliability of SiC-based hybrid IGBT modules is crucial for ensuring the long-term stability of high-power electronic systems, particularly under cyclic thermal stress. While prior research has extensively investigated traditional solder materials and individual reliability factors, these studies often lack comprehensive optimization strategies. To address this gap, the present study systematically enhances module reliability by combining finite element analysis (FEA) with the Taguchi optimization method. The focus is on enhancing the durability of solder interconnects under severe thermal cycling conditions, ranging from −40 °C to 125 °C. This work is novel in integrating nano-silver solder evaluation and optimization of Direct Bonded Copper (DBC) liner materials within a structured optimization framework, which significantly differentiates from previous studies. The results indicate that von Mises stresses are concentrated at the chip solder edges, reaching up to 157 MPa, which exceeds the yield strength and accelerates fatigue. The fatigue life predictions based on Engelmaier’s modified Coffin-Manson model show that nano-silver solder extends the module’s lifespan by approximately 90 % compared to conventional SAC305 solder. Additionally, the optimization results suggest that Si<sub>3</sub>N<sub>4</sub> liners effectively reduce peak stress. These insights provide guidelines for designing highly durable SiC-based IGBT modules applicable to electric vehicles, renewable energy systems, and high-power converters.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109619"},"PeriodicalIF":4.4,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143863429","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}

引用次数: 0

Coupling effect of manufacturing and creep on remaining strength of 2.25Cr-1Mo-0.25 V steel ring shells

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-18 DOI: 10.1016/j.engfailanal.2025.109615

You Li , Bieerlan Jianayihan , Song Huang , Endong Wu , Chaoxu Guan , Zhenyu Wang

Manufacturing and creep inevitably cause material degradation and a subsequent decline in the performance of 2.25Cr-1Mo-0.25 V steel ring shells. However, their combined effect remains inadequately understood, leading to a paucity of reliable assessment methods. The present study introduced an innovative approach to investigate the coupling effect of manufacturing and creep on the remaining strength of 2.25Cr-1Mo-0.25 V steel ring shells. Firstly, a series of experiments—including pre-strain tests, heat treatments, interrupted creep tests, and tensile tests—were carefully conducted. Results indicated that the high-temperature strength of 2.25Cr-1Mo-0.25 V steel initially increases with extended creep duration, followed by a subsequent decrease. In contrast, a consistent reduction in strength is observed as warm deformation increases. Secondly, a novel approach was developed for predicting remaining strength, incorporating the coupling effect of manufacturing and creep. This approach integrates a data-driven model for strength prediction, finite element simulation of forming, and a direct technique for limit load analysis. Finally, the strength distribution and evolution of 2.25Cr-1Mo-0.25 V steel ring shells, along with their load-bearing capacity, were calculated and analyzed. Numerical analyses revealed that manufacturing induces material strength inhomogeneity in 2.25Cr-1Mo-0.25 V steel ring shells. Additionally, during prolonged creep aging, the central regions of the ring shells consistently demonstrate superior performance compared to the surface regions. As for load-bearing capacity, manufacturing is associated with a reduction of 20 % to 30 %, whereas creep initially results in an increase of up to 10 %, followed by a subsequent decrease of 25 %. Furthermore, a diminished diameter-to-thickness ratio is correlated with an increased likelihood of premature failure. This work contributes to the safety assessments of high-temperature hydrogen-bearing pressure vessels.

{"title":"Coupling effect of manufacturing and creep on remaining strength of 2.25Cr-1Mo-0.25 V steel ring shells","authors":"You Li , Bieerlan Jianayihan , Song Huang , Endong Wu , Chaoxu Guan , Zhenyu Wang","doi":"10.1016/j.engfailanal.2025.109615","DOIUrl":"10.1016/j.engfailanal.2025.109615","url":null,"abstract":"<div><div>Manufacturing and creep inevitably cause material degradation and a subsequent decline in the performance of 2.25Cr-1Mo-0.25 V steel ring shells. However, their combined effect remains inadequately understood, leading to a paucity of reliable assessment methods. The present study introduced an innovative approach to investigate the coupling effect of manufacturing and creep on the remaining strength of 2.25Cr-1Mo-0.25 V steel ring shells. Firstly, a series of experiments—including pre-strain tests, heat treatments, interrupted creep tests, and tensile tests—were carefully conducted. Results indicated that the high-temperature strength of 2.25Cr-1Mo-0.25 V steel initially increases with extended creep duration, followed by a subsequent decrease. In contrast, a consistent reduction in strength is observed as warm deformation increases. Secondly, a novel approach was developed for predicting remaining strength, incorporating the coupling effect of manufacturing and creep. This approach integrates a data-driven model for strength prediction, finite element simulation of forming, and a direct technique for limit load analysis. Finally, the strength distribution and evolution of 2.25Cr-1Mo-0.25 V steel ring shells, along with their load-bearing capacity, were calculated and analyzed. Numerical analyses revealed that manufacturing induces material strength inhomogeneity in 2.25Cr-1Mo-0.25 V steel ring shells. Additionally, during prolonged creep aging, the central regions of the ring shells consistently demonstrate superior performance compared to the surface regions. As for load-bearing capacity, manufacturing is associated with a reduction of 20 % to 30 %, whereas creep initially results in an increase of up to 10 %, followed by a subsequent decrease of 25 %. Furthermore, a diminished diameter-to-thickness ratio is correlated with an increased likelihood of premature failure. This work contributes to the safety assessments of high-temperature hydrogen-bearing pressure vessels.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109615"},"PeriodicalIF":4.4,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860379","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}

引用次数: 0

Multivariate damage mode identification method for fiber-reinforced composites at high temperatures by acoustic emission

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-18 DOI: 10.1016/j.engfailanal.2025.109618

Xiaodong Liu , Kai Huang , Yuhang Liu , Li Zhang , Xiaojian Han , Jindi Zhou , Hongsen Liu , Licheng Guo

Carbon fiber reinforced polymers (CFRPs) often operate in high-temperature environments, which significantly influence their damage evolution behavior and mechanical performance. To investigate this effect, a multivariable damage mode identification (MDMI) method utilizing acoustic emission (AE) technology, applicable to high-temperature conditions, is proposed. Four specimen types inducing distinct primary damage modes are designed, and mechanical tests under different temperatures are conducted to accurately extract AE signal features for each damage mode, confirming the reliability of the MDMI method. Results indicate that temperature has minimal effect on the peak frequency range for each damage mode but significantly reduces the signal amplitude in the frequency domain. Using the MDMI method, the compressive performance of open-hole CFRPs is analyzed under different temperatures. As temperature rises, the dominant damage mode of open-hole CFRPs under compression transitions from fiber/matrix debonding to predominantly matrix cracking. This study provides valuable insights into damage mode identification of CFRP under different temperatures, offering significant guidance for predicting and optimizing its performance in extreme environments.

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引用次数: 0

Root cause analysis of turboprop engine Inconel 713LC turbine blades failure

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-17 DOI: 10.1016/j.engfailanal.2025.109609

Georgios Chondrakis , Athanasios Tzanis , Emmanuel Georgiou , Angelos Koutsomichalis

In this paper, the root cause analysis of failed Inconel 713LC superalloy blades with approximately 3500 flight hours since new from the stage Ι of power turbine is presented. A two-stage axial-flow power turbine driving the propeller of an aircraft turboprop engine through an internal shaft, during take-off at altitude of 600 feet experienced an in-flight shutdown. At the time of the incident the rotational speed of power turbine was at 90 % torque rotating at approximately 1,300 rpm, having operating temperatures above 950 °C. The failure occurred after 120 operating hours from the last engine overhaul inspection. To examine the root of this catastrophic failure, both fractographic and metallographic examinations were performed by various means. It was found that four successive blades of the stage Ι turbine disk initially fractured by fatigue mechanism and then by overload. Fatigue initiation sites were observed mainly at the leading edge of those four blades, where coating degradation appears due to a synergism between thermal fatigue cracking and corrosion that extends through the coating and into the blade base material. Microstructural analysis performed at these four blades revealed solutioning and coarsening of the nickel superalloy gamma prime phase and intergranular creep voids, indicating long-term exposure to high temperature. The remaining 62 blades were subsequently fractured by overload due to impact damage from the fragments. From these examinations, it is concluded that the fatigue cracks on the four turbine blades initiated from the combination of thermal fatigue and corrosion. Subsequently, the cracks propagated by a mix of creep and fatigue due to coating and microstructure degradation caused by overheating.

{"title":"Root cause analysis of turboprop engine Inconel 713LC turbine blades failure","authors":"Georgios Chondrakis , Athanasios Tzanis , Emmanuel Georgiou , Angelos Koutsomichalis","doi":"10.1016/j.engfailanal.2025.109609","DOIUrl":"10.1016/j.engfailanal.2025.109609","url":null,"abstract":"<div><div>In this paper, the root cause analysis of failed Inconel 713LC superalloy blades with approximately 3500 flight hours since new from the stage Ι of power turbine is presented. A two-stage axial-flow power turbine driving the propeller of an aircraft turboprop engine through an internal shaft, during take-off at altitude of 600 feet experienced an in-flight shutdown. At the time of the incident the rotational speed of power turbine was at 90 % torque rotating at approximately 1,300 rpm, having operating temperatures above 950 °C. The failure occurred after 120 operating hours from the last engine overhaul inspection. To examine the root of this catastrophic failure, both fractographic and metallographic examinations were performed by various means. It was found that four successive blades of the stage Ι turbine disk initially fractured by fatigue mechanism and then by overload. Fatigue initiation sites were observed mainly at the leading edge of those four blades, where coating degradation appears due to a synergism between thermal fatigue cracking and corrosion that extends through the coating and into the blade base material. Microstructural analysis performed at these four blades revealed solutioning and coarsening of the nickel superalloy gamma prime phase and intergranular creep voids, indicating long-term exposure to high temperature. The remaining 62 blades were subsequently fractured by overload due to impact damage from the fragments. From these examinations, it is concluded that the fatigue cracks on the four turbine blades initiated from the combination of thermal fatigue and corrosion. Subsequently, the cracks propagated by a mix of creep and fatigue due to coating and microstructure degradation caused by overheating.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109609"},"PeriodicalIF":4.4,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143848478","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}

引用次数: 0

Rock-crushing mechanism caused by TBM ball-tooth cutter in water jet slotting condition

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-04-17 DOI: 10.1016/j.engfailanal.2025.109616

Xuhui Zhang , Zeren Peng , Hanwen Lai , Hengxing Zhong , Yashi Liao , Jianfang Li , Yimin Xia

To study the rock-crushing mechanism of the TBM ball-tooth cutter in water jet slotting condition, the rock-crushing process and phenomenon in slotting condition was simulated and observed with finite element simulation and experimental test, respectively. Then, the difference in rock-crushing features in varying slot depths and cut breadths were compared. The research findings indicate that the rock surface exhibits some intermittent pits in the cut trajectory while the ball-tooth cutter cut rock in slotting condition. For a certain slot depth, there exists a critical cut breadth within which the slotting condition has an auxiliary effect for the ball-tooth cutter. While the cut breadth is beyond the critical cut breadth, the auxiliary effect of the slotting condition will disappear. The critical cut breadths for the ball-tooth cutter at slot depths of 5 mm, 15 mm, 25 mm, and 35 mm are 20 mm, 30 mm, 30 mm, and 40 mm, respectively. At a certain slot depth condition, both the vertical and tangential loads rise then stabilize, but the side load firstly reduces and eventually stabilize with the growth of the cut breadth. Furthermore, the efficiency index initially grows with the growth of the cut breadth, but after reaching a peak, it begins to reduce and ultimately stabilizes. For each slot depth, there exists an optimal cut breadth that maximizes the efficiency index and enhances rock-crushing efficiency, and the optimal cut breadth corresponds to the critical cut breadth. Additionally, for a certain cut breadth which is below the critical cut breadth, both the vertical load and the tangential load tend to reduce, whereas the average side load and efficiency index of the ball-tooth cutter show an upward trend with the growth of slot depth from 5 mm to 35 mm. While for the certain cut breadth which is beyond the critical cut breadth, both the rock-crushing loads and efficiency index of the ball-tooth cutter under varying slot depth are similar. Overall, by the assist of water jet slotting condition, the rock-crushing loads and the efficiency index of the ball-tooth cutter could be evidently improved.

{"title":"Rock-crushing mechanism caused by TBM ball-tooth cutter in water jet slotting condition","authors":"Xuhui Zhang , Zeren Peng , Hanwen Lai , Hengxing Zhong , Yashi Liao , Jianfang Li , Yimin Xia","doi":"10.1016/j.engfailanal.2025.109616","DOIUrl":"10.1016/j.engfailanal.2025.109616","url":null,"abstract":"<div><div>To study the rock-crushing mechanism of the TBM ball-tooth cutter in water jet slotting condition, the rock-crushing process and phenomenon in slotting condition was simulated and observed with finite element simulation and experimental test, respectively. Then, the difference in rock-crushing features in varying slot depths and cut breadths were compared. The research findings indicate that the rock surface exhibits some intermittent pits in the cut trajectory while the ball-tooth cutter cut rock in slotting condition. For a certain slot depth, there exists a critical cut breadth within which the slotting condition has an auxiliary effect for the ball-tooth cutter. While the cut breadth is beyond the critical cut breadth, the auxiliary effect of the slotting condition will disappear. The critical cut breadths for the ball-tooth cutter at slot depths of 5 mm, 15 mm, 25 mm, and 35 mm are 20 mm, 30 mm, 30 mm, and 40 mm, respectively. At a certain slot depth condition, both the vertical and tangential loads rise then stabilize, but the side load firstly reduces and eventually stabilize with the growth of the cut breadth. Furthermore, the efficiency index initially grows with the growth of the cut breadth, but after reaching a peak, it begins to reduce and ultimately stabilizes. For each slot depth, there exists an optimal cut breadth that maximizes the efficiency index and enhances rock-crushing efficiency, and the optimal cut breadth corresponds to the critical cut breadth. Additionally, for a certain cut breadth which is below the critical cut breadth, both the vertical load and the tangential load tend to reduce, whereas the average side load and efficiency index of the ball-tooth cutter show an upward trend with the growth of slot depth from 5 mm to 35 mm. While for the certain cut breadth which is beyond the critical cut breadth, both the rock-crushing loads and efficiency index of the ball-tooth cutter under varying slot depth are similar. Overall, by the assist of water jet slotting condition, the rock-crushing loads and the efficiency index of the ball-tooth cutter could be evidently improved.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"176 ","pages":"Article 109616"},"PeriodicalIF":4.4,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143850407","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}

引用次数: 0