Engineering Failure Analysis最新文献_第10页

Collapse failure analysis of the single-layer reticulated shell dome for a large-scale slag oil tank 某大型渣油罐单层网壳顶棚倒塌破坏分析

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-15 DOI: 10.1016/j.engfailanal.2025.110464

Fan Zhou , Lingyang Kong , Tianliang Huang , Yanling Zhao , Yang Du

The failure mechanisms and root causes of the collapse of the single-layer reticulated shell dome for a 30,000 m³ slag oil tank were explored. Specifically, macro–micro characterization and physicochemical testing were conducted on the key components of plate joint (including tie rods, gusset plates and bolts) were carried out. Meanwhile, stability analysis of the reticulated shell dome considering geometric nonlinearity was carried out by numerical simulation. And finally, load verification was performed on the bolts. The results show that the physical, chemical, and mechanical properties of the materials for tie rods, gusset plates and bolts all meet the requirements of relevant standards. The predicted critical instability load of the dome is 6.18 times the actual load it bears, which rules out the possibility of the dome collapsing due to the overall stability failure. Analysis indicates that extreme weather (strong winds and heavy rains) and the additional approximately 70-ton concrete waterproof structure led to an excessive actual negative pressure load on the reticulated shell, which in turn caused the shear fracture of the bolts in the plate joints. After the failure of a single joint, load redistribution among adjacent joints was triggered, eventually resulting in the overall collapse of the reticulated shell dome. The incorrect design of bolts in the plate joint system and their insufficient shear strength are the root causes of this dome collapse accident. In addition, suggestions are also put forward to avoid similar collapse accidents for large-scale storage tanks with reticulated shell domes.

探讨了某3万m3矿渣油罐单层网壳穹顶坍塌的破坏机理及根本原因。具体而言，对板节点关键部件（包括拉杆、扣板和螺栓）进行了宏观微观表征和理化测试。同时，通过数值模拟对考虑几何非线性的网壳穹顶进行了稳定性分析。最后对螺栓进行荷载验证。结果表明，拉杆、扣板和螺栓材料的物理、化学和力学性能均符合相关标准的要求。预测的穹顶临界失稳荷载是其实际承受荷载的6.18倍，排除了穹顶整体失稳而坍塌的可能性。分析表明，极端天气（强风和暴雨）和额外的约70吨混凝土防水结构导致网壳实际负压载荷过大，从而导致板缝螺栓剪切断裂。单个节点破坏后，引发相邻节点间荷载重分布，最终导致网壳穹顶整体倒塌。板节点系统螺栓设计不当，抗剪强度不足是造成本次拱顶坍塌事故的根本原因。此外，还对大型网壳储罐的倒塌事故提出了避免类似事故的建议。

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引用次数: 0

Al-induced network rust structure enhancing the corrosion resistance of Fe-4Al steel in tropical marine atmospheres 铝致网状锈蚀结构提高了Fe-4Al钢在热带海洋大气中的耐蚀性

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-15 DOI: 10.1016/j.engfailanal.2025.110467

Yongzhe Yang , Xueliang Shang , Jinghua Cong , Xiangyu Xu , Xuemin Wang

This study investigates the differences in corrosion behavior between Fe-4Al (wt.%) steel and an ordinary weathering steel (Corten-A) in a tropical marine environment. The structure, elemental distribution, and phases of the rust layer were analyzed using SEM, EDS, XPS, and XRD. The results showed that Fe-4Al steel has better corrosion resistance compared to Corten-A. The corrosion rate of Corten-A at 2 years of exposure is 3.2 times that of 4Al. The Al element is significantly enriched within the rust layer and is present in the form of AlOOH and Al(OH)₃. AlOOH provides numerous nucleation sites, inducing the formation and interwoven growth of FeOOH network structures within the Al rich regions. This network structure can hinder the propagation of microcracks in the rust layer and enhance the adhesion of the rust layer. Furthermore, the adsorption capacity of Al(OH)₃ for Cl^–, combined with the aforementioned effects of AlOOH, results in a denser rust layer that can effectively resist Cl^– intrusion and promote the formation of more α-FeOOH. Consequently, the rust layer of Fe-4Al steel plays a more effective protective role.

本研究调查了Fe-4Al （wt.%）钢和普通耐候钢（Corten-A）在热带海洋环境中的腐蚀行为差异。采用SEM、EDS、XPS和XRD分析了锈层的结构、元素分布和物相。结果表明，Fe-4Al钢比Corten-A具有更好的耐蚀性。暴露2年时，Corten-A的腐蚀速率是4Al的3.2倍。铝元素在锈层内显著富集，并以AlOOH和Al(OH)3的形式存在。AlOOH提供了大量的成核位点，诱导富Al区域内FeOOH网络结构的形成和交织生长。这种网状结构可以阻碍锈层微裂纹的扩展，增强锈层的附着力。此外，Al(OH)3对Cl -的吸附能力，加上AlOOH的上述作用，导致锈层更致密，可以有效抵抗Cl -的侵入，促进α-FeOOH的形成。因此，Fe-4Al钢的防锈层起到了更有效的保护作用。

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引用次数: 0

Synergistic mechanism of laser-ultrasonic elliptical vibration on turning damage suppression in SiCp/Al composites 激光超声椭圆振动抑制SiCp/Al复合材料车削损伤的协同机理

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-16 DOI: 10.1016/j.engfailanal.2025.110466

Peicheng Peng , Xiaolong Tian , Heshuai Yu , Wenbo Bie , Yashan Feng , Chen Li , Ke Niu , Daohui Xiang , Guofu Gao

A newly proposed laser-ultrasonic elliptical vibration turning (LUEVT) process was designed to suppress damage in conventionally machined SiCp/Al composites. To account for the material’s heterogeneous structure, a finite element model (FEM) with randomly distributed SiC particles was established to simulate the LUEVT process of SiCp/Al composites. By combining numerical simulations with experimental tests, the mechanisms of machining damage initiation, damage suppression, and material removal were explored, with a focus on the synergistic effects of laser thermal softening and ultrasonic elliptical vibration. The results showed that the laser heating can increased thermal flux of the material, causing it to soften and enhancing chip continuity. Ultrasonic elliptical vibration significantly alleviated stress, reduced the depth of crack propagation, and thus improved the plastic removal ability, effectively suppressing machining damage. Concurrently, these two synergistic effects mitigate the cutting force’s magnitude and its associated fluctuations.

为了抑制SiCp/Al复合材料的损伤，设计了一种新的激光超声椭圆振动车削工艺。为了考虑材料的非均相结构，建立了SiC颗粒随机分布的有限元模型，模拟了SiCp/Al复合材料的LUEVT过程。通过数值模拟与实验试验相结合的方法，探讨了激光热软化与超声椭圆振动的协同作用对加工损伤产生、损伤抑制和材料去除的影响机理。结果表明，激光加热可以增加材料的热流通量，使材料软化，增强切屑的连续性。超声椭圆振动显著缓解应力，减小裂纹扩展深度，从而提高塑性去除能力，有效抑制加工损伤。同时，这两种协同效应减轻了切削力的大小及其相关波动。

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引用次数: 0

Ductile fracture behavior of X65 pipeline steel under different stress states 不同应力状态下X65管线钢的韧性断裂行为

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-09 DOI: 10.1016/j.engfailanal.2025.110449

Yongxin Xu , Xingfeng Liu , Lianmin Cao , Jian Chen , Guiyi Wu , Ying Zhen , Yuguang Cao

Experimental tests and numerical simulations on tensile specimens with different geometries were carried out to investigate the ductile fracture behavior of pipeline steel under various stress states. Based on uniaxial tensile test data, the damage parameters of the MMC damage model were calibrated using a genetic-algorithm-based optimization procedure. After calibration, numerical simulations of uniaxial tensile specimens with different geometries were performed, and their fracture behavior under different stress states was studied in combination with experiments. The results show that the numerical simulations agree very well with the experimental data: the error in fracture displacement is less than 8.04%, and the average load error in the plastic regime is within 4.36%, which confirms the predictive capability of the MMC model for fracture behavior under different stress states. The significant influence of stress triaxiality and the normalized Lode angle parameter on fracture strain and failure mode is discussed. At low stress triaxiality, the material mainly exhibits shear fracture, and as the stress triaxiality increases, the fracture mode gradually transitions from shear-dominated to tension-dominated fracture. Under tension-dominated stress states, a smaller notch radius leads to higher stress triaxiality and a pronounced reduction in plastic deformation capacity. By further correlating stress paths with crack propagation trajectories and fracture morphologies, the continuous transition mechanism of X65 pipeline steel from low-triaxiality shear-dominated fracture to high-triaxiality tension-dominated fracture is revealed, demonstrating that the MMC damage model can provide a unified description of fracture modes under multiple stress paths. This study provides a reliable prediction method for the ductile fracture behavior of X65 pipeline steel and offers a reference for establishing a mapping between stress state, fracture mode, and fracture morphology of X65 pipeline steel.

为研究管道钢在不同应力状态下的韧性断裂行为，对不同几何形状的拉伸试样进行了实验试验和数值模拟。基于单轴拉伸试验数据，采用遗传算法对MMC损伤模型的损伤参数进行了标定。标定后，对不同几何形状的单轴拉伸试样进行数值模拟，并结合实验研究其在不同应力状态下的断裂行为。结果表明，数值模拟结果与试验数据吻合较好，裂缝位移误差小于8.04%，塑性区平均载荷误差在4.36%以内，证实了MMC模型对不同应力状态下断裂行为的预测能力。讨论了应力三轴性和归一化Lode角参数对断裂应变和破坏模式的显著影响。在低应力三轴性下，材料主要表现为剪切断裂，随着应力三轴性的增大，断裂模式逐渐由剪切为主转变为拉伸为主。在以拉为主的应力状态下，缺口半径越小，应力三轴性越高，塑性变形能力显著降低。通过进一步将应力路径与裂纹扩展轨迹和断裂形态联系起来，揭示了X65管线钢从低三轴剪切为主断裂到高三轴拉伸为主断裂的连续过渡机制，表明MMC损伤模型能够统一描述多种应力路径下的断裂模式。本研究为X65管线钢韧性断裂行为提供了可靠的预测方法，为建立X65管线钢的应力状态、断裂模式和断口形貌之间的映射关系提供了参考。

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引用次数: 0

Structural failure analysis of wind turbines in 2024 Greenfield tornado 2024格林菲尔德龙卷风中风力发电机结构失效分析

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-11-25 DOI: 10.1016/j.engfailanal.2025.110387

Muhammad Usama Aslam, Alice Alipour

Tornadoes present a critical hazard to energy infrastructure, with their extreme wind speeds and complex three dimensional velocity structures making accurate structural assessment and modeling exceptionally challenging. This study focuses on the structural failure mechanisms of utility-scale wind turbines impacted by tornado-induced loads, with a detailed case study of the wind turbines damaged during the 2024 Greenfield tornado. Combining forensic field investigations with advanced finite element modeling, this research systematically examines failure modes in both the turbine tower and blades. Field damage observations, including tower buckling and localized plastic deformation, were validated through finite element analysis, which confirmed that local inelastic buckling driven by stress concentrations near geometric discontinuities was the primary failure mechanism. Three key parametric studies were conducted: influence of the characteristic height of maximum radial velocity on applied wind loading; effect of lateral offset from tornado path center on structural damage severity; and role of tower wall thickness in enhancing resistance to tornado-induced loads.

Findings from these analyses directly inform recommendations for improved tower designs in tornado-prone regions. The study also highlights limitations in the existing wind turbine standards, which currently overlook tornado-specific loading scenarios, and advocates for incorporating tornado-resistant design provisions and revised safety factors. Overall, this work advances the understanding of tornado-induced structural vulnerabilities in wind turbines and provides actionable insights to enhance the resilience and reliability of wind energy infrastructure in tornado prone regions.

龙卷风对能源基础设施构成严重威胁，其极端的风速和复杂的三维速度结构使得准确的结构评估和建模非常具有挑战性。本研究重点研究了公用事业规模风力发电机组在龙卷风荷载作用下的结构破坏机制，并对2024年格林菲尔德龙卷风期间受损的风力发电机组进行了详细的案例研究。结合现场调查和先进的有限元模型，本研究系统地检查了涡轮塔和叶片的失效模式。通过有限元分析验证了现场损伤观测结果，包括塔架屈曲和局部塑性变形，证实了几何不连续附近应力集中驱动的局部非弹性屈曲是主要破坏机制。进行了三个关键参数研究：最大径向速度特征高度对外加风荷载的影响；龙卷风路径中心侧向偏移对结构破坏程度的影响塔壁厚度对提高塔抗龙卷风荷载的作用。这些分析的结果直接为龙卷风易发地区改进塔的设计提供了建议。该研究还强调了现有风力涡轮机标准的局限性，这些标准目前忽视了龙卷风特定载荷的情况，并主张纳入抗龙卷风的设计条款和修订的安全系数。总的来说，这项工作促进了对龙卷风引起的风力涡轮机结构脆弱性的理解，并为增强龙卷风易发地区风能基础设施的恢复力和可靠性提供了可行的见解。

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引用次数: 0

Research on the cracking mechanism in self-piercing riveting between non-heat-treated die-casting aluminum alloy and steel sheets 非热处理压铸铝合金与钢板自穿孔铆接开裂机理研究

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-03 DOI: 10.1016/j.engfailanal.2025.110402

Yong Zhang, Junfei Yan, Bengang Yi, Hongsheng Tian, Yijiao Sun, Na Xi

Large-scale integrated die-casting has been widely adopted in automotive body structure design. To minimize structural deformation during heat treatment and meet crash safety standards, non-heat-treated (NHT) die-casting aluminum alloys have become the preferred material for large-scale die-casting structural components. Compared to conventional heat-treatable die-casting aluminum alloys, these NHT variants exhibit superior mechanical properties without additional heat treatment processing, while retaining excellent castability. However, they generally display reduced ductility. Experimental results indicate that materials with low ductility are prone to cracking during self-piercing riveting (SPR), which critically affects joint quality and reliability. This study establishes a two-dimensional finite element model to investigate the cracking mechanism of NHT die-casting aluminum alloys when riveted to steel sheets. The finite element model simulates the riveting process and enables detailed analysis of crack initiation and propagation within the bottom sheet. Critical joint performance metrics such as interlock, head height, and residual bottom thickness are also evaluated. Experimental validation confirms the model’s accuracy. Utilizing the validated model, the relationship between damage accumulation in the bottom sheet and its stress state and plastic strain is further explored. The fundamental mechanisms governing cracking during SPR in these alloys are identified. Moreover, a method for selecting suitable rivet dies for NHT die-casting aluminum alloys is proposed and verified.

大型一体化压铸在汽车车身结构设计中得到了广泛的应用。为了减少热处理过程中的结构变形，满足碰撞安全标准，非热处理压铸铝合金已成为大型压铸结构部件的首选材料。与传统的可热处理压铸铝合金相比，这些NHT变体在没有额外热处理处理的情况下表现出优越的机械性能，同时保持了优异的浇注性。然而，它们通常表现出较低的延展性。试验结果表明，低延性材料在自穿孔铆接过程中容易产生裂纹，严重影响接头质量和可靠性。建立了二维有限元模型，研究了NHT压铸铝合金与钢板铆接时的开裂机理。有限元模型模拟了铆接过程，并能够详细分析底板内裂纹的萌生和扩展。关键的接头性能指标，如联锁，水头高度和剩余底部厚度也进行了评估。实验验证了模型的准确性。利用验证模型，进一步探讨了底板损伤累积与底板应力状态和塑性应变的关系。确定了这些合金在SPR过程中控制裂纹的基本机制。提出了一种适合NHT压铸铝合金铆钉模具的选择方法，并进行了验证。

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引用次数: 0

Study on fracture mechanism and damage degree of GFRP/steel–concrete hybrid girder by acoustic emission technology 基于声发射技术的玻璃钢/钢-混凝土混合梁断裂机理及损伤程度研究

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-10 DOI: 10.1016/j.engfailanal.2025.110450

Jiashuo Teng , Fangzhu Du , Wei Shen , Dapeng Qiu

This study investigated fracture mechanisms and quantified damage progression in GFRP/steel–concrete hybrid girders using advanced acoustic emission (AE) technology. A novel two-step filtering strategy was proposed to mitigate the negative influence of interference signals and enhance the reliability of structural failure analysis. The variation of basic AE parameters accurately reflected the evolutionary mechanisms and demonstrated sensitivity to sudden damage. Derivative indicators, such as the RA-AF, b-value, and sentry function, effectively discerned failure modes and assessed the damage degree. The comprehensive analysis integrating basic AE parameters with these derivative indicators was recommended to enhance the reliability of damage assessment beyond sole-indicator analysis. Furthermore, a thorough discussion determined the rational threshold values for the T-filter and IF-filter. It also confirmed that employing the WD sensor with a threshold of 50 dB in the AE system represents a wise choice for long-term structural health monitoring applications.

本研究采用先进声发射（AE）技术研究了玻璃钢/钢-混凝土混合梁的断裂机制和量化损伤进展。为了减轻干扰信号的负面影响，提高结构失效分析的可靠性，提出了一种新的两步滤波策略。基本声发射参数的变化准确反映了演化机制，对突发性损伤表现出敏感性。衍生指标，如RA-AF、b值、岗哨函数等，可以有效识别失效模式，评估损伤程度。建议采用声发射基本参数与这些衍生指标相结合的综合分析方法，以提高损伤评估的可靠性。进一步，通过深入的讨论确定了t滤波器和if滤波器的合理阈值。研究还证实，在声发射系统中采用阈值为50 dB的WD传感器是长期结构健康监测应用的明智选择。

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引用次数: 0

Failure mechanism transition from fatigue spallation to oxidative wear in age-hardened Ni3x(FeCr)yCo(x+y)/2 high-entropy alloys produced by laser directed energy deposition at elevated temperature 高温激光定向能沉积时效硬化Ni3x(FeCr)yCo(x+y)/2高熵合金失效机制由疲劳裂裂向氧化磨损转变

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2026-01-12 DOI: 10.1016/j.engfailanal.2026.110577

Hao Liu , Bin Wang , Dali Li , Binxin Dong , Jian Liu , Peijian Chen , Yanhua Bian , Qiansheng Xu , Yu Fan , Xiuli He

High-temperature friction and wear–induced degradation of structural materials is a major factor limiting the service life of critical components operating under severe thermal conditions. In this study, Ni_3x(FeCr)_yCo_(x+y)/2 high-entropy alloys (HEAs) with x/y ratios of 0.5, 0.75, 1.0, and 1.5 were fabricated using laser directed energy deposition (LDED). The objective was to regulate the transition of high-temperature wear-induced failure mechanisms through compositional tuning and age-hardening treatment. The as-deposited alloys consist of an FCC-structured γ matrix and an HCP-structured Laves phase, whose volume fraction decreases with increasing x/y ratio. Age-hardening actively modulates the microstructure, promoting partial dissolution of the Laves phase and the precipitation of nanoscale L1₂-type γ′ coherent particles. The microhardness of the aged alloys increases with the x/y ratio and is markedly higher than that of the as-deposited condition. High-temperature (600 °C) tribological tests reveal that the wear rate of the as-deposited alloys first increases and then decreases with the x/y ratio, whereas that of the aged alloys decreases monotonically, reaching a minimum value of 3.53 × 10⁻⁵ mm³/(N·m) at x/y = 1.5. Age-hardening strengthens the matrix and facilitates the formation of a dense oxide film enriched in Ni and Al, effectively suppressing fatigue-induced spallation of the oxide film. This study shows that tuning composition and applying age-hardening can actively control high-temperature wear failure modes, offering guidance for designing materials with superior high-temperature wear resistance.

结构材料的高温摩擦和磨损退化是限制在高温条件下运行的关键部件使用寿命的主要因素。采用激光定向能沉积（LDED）法制备了x/y比值分别为0.5、0.75、1.0和1.5的Ni3x(FeCr)yCo(x+y)/2高熵合金（HEAs）。目的是通过成分调整和时效硬化处理来调节高温磨损失效机制的转变。沉积合金由fcc组织的γ基体和hcp组织的Laves相组成，其体积分数随x/y比的增大而减小。时效硬化积极调节微观组织，促进Laves相的部分溶解和纳米级l12型γ′相干颗粒的析出。时效合金的显微硬度随x/y比值的增大而增大，且明显高于沉积状态。高温（600℃）摩擦学试验表明，随x/y比的增大，沉积态合金的磨损率先增大后减小，时效态合金的磨损率单调减小，在x/y = 1.5时达到最小值3.53 × 10−5 mm3/（N·m）。时效硬化强化了基体，促进了富含Ni和Al的致密氧化膜的形成，有效地抑制了疲劳引起的氧化膜剥落。研究表明，调整成分和时效硬化可以有效地控制高温磨损失效模式，为设计具有优异高温耐磨性的材料提供指导。

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引用次数: 0

Study on acoustic characteristics of bearings with outer ring raceway electrical corrosion fault 外圈滚道电气腐蚀故障轴承声学特性研究

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-24 DOI: 10.1016/j.engfailanal.2025.110504

Peng Wang , Zhaowei Zhang , Rongzheng Zou , Xuegang Li , Yuxin Dong

As a typical distributed fault of bearings, the raceway electric corrosion fault consists of multi-groove faults formed by the striking and erosion of shaft currents, which provides a practical basis for the acoustic feature-based identification of bearing electric erosion fault states. This paper presents a continuous nonlinear electrical corrosion grooves (ECGs) model to simulate the morphology of electric corrosion faults on the outer ring inner raceway of bearings. By combining this model with mechanical theory, the forces acting on components under electric erosion conditions are described, and a dynamic model is developed. Based on the sub-source decomposition method, noise sources generated by vibration excitation are superimposed, and dual verification is conducted through comparative analysis and experimental validation: the increase in vibration excitation caused by the aggravation of electric corrosion is the main reason for the increase in sound pressure, and the overall sound pressure level shows a “cumulative enhancement” trend with the increase in the number of ECGs. In addition, the modulation frequency distribution of the noise signal at the central reference point can be used to diagnose the occurrence of electric corrosion faults. The research uncovers the mechanisms behind the acoustic characteristics of bearing raceway electric corrosion faults. A dynamic model that includes electrical corrosion faults has been developed for the first time, providing an theoretical framework for identifying electric corrosion fault.

滚道电蚀故障是一种典型的轴承分布故障，由轴流冲击和冲刷形成的多沟槽故障组成，为基于声特征的轴承电蚀故障状态识别提供了实践依据。提出了一种连续非线性电腐蚀槽（ECGs）模型，用于模拟轴承外圈内滚道电腐蚀故障的形貌。将该模型与力学理论相结合，描述了电侵蚀条件下作用在构件上的力，并建立了一个动力学模型。基于子源分解方法，对振动激励产生的噪声源进行叠加，通过对比分析和实验验证进行双重验证：电腐蚀加剧引起的振动激励增加是声压增加的主要原因，整体声压级随着ecg数量的增加呈现“累积增强”的趋势。此外，噪声信号在中心参考点的调制频率分布可用于诊断电气腐蚀故障的发生。研究揭示了轴承滚道电腐蚀故障的声学特性背后的机理。首次建立了包含电腐蚀故障的动力学模型，为电腐蚀故障识别提供了理论框架。

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引用次数: 0

Failure analysis and service life prediction of condensate oil pump impellers in atmospheric-vacuum distillation units 常减压蒸馏装置冷凝油泵叶轮失效分析及寿命预测

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-03-15 Epub Date: 2025-12-16 DOI: 10.1016/j.engfailanal.2025.110469

Jinqiang Shao , Jin Zhou , Jiaxing Zhang , Xiaoxiao Dong

Cracks appeared in the impeller of condensing oil pump in atmospheric and vacuum distillation unit of a petrochemical company after nine years of normal use, which is one of the failure modes that petrochemical rotating machinery may face after long-term service. In this paper, firstly, the macro-fracture morphology, microstructure, micro-fracture surface morphology and chemical composition of the impeller are systematically analyzed. The analysis results show that the impeller cracking belongs to intergranular cracking, which is mainly caused by unqualified casting quality and a large number of casting defects in the impeller, especially the columnar crystals and grain boundaries with large grains in the impeller wall have low grain boundary strength due to segregation. Then, by using computational fluid dynamics (CFD), the fluid–solid coupling calculation will be carried out on the impeller made of qualified materials from centrifugal force and fluid pulsating load, and the maximum stress on the impeller is located at the root position at the junction of the blade and the cover plate and at the outlet edge of the blade, and the maximum stress points in different areas of the impeller are selected to predict the fatigue life. This study has certain reference value for the failure analysis of centrifugal pump impeller with casting defects, and puts forward some maintenance suggestions.

某石化公司常减压蒸馏装置冷凝油泵叶轮在正常使用9年后出现裂纹，是石化旋转机械长期使用后可能面临的故障模式之一。本文首先对叶轮的宏观断口形貌、微观组织、微观断口形貌及化学成分进行了系统分析。分析结果表明，叶轮裂纹属于晶间裂纹，主要是由于铸造质量不合格和叶轮中存在大量铸造缺陷造成的，特别是叶轮内壁存在较大晶粒的柱状晶和晶界，由于偏析导致晶界强度较低。然后，利用计算流体动力学（CFD）对离心力和流体脉动载荷作用下的合格材料制成的叶轮进行流固耦合计算，叶轮上的最大应力位于叶片与盖板交界处根部位置和叶片出口边缘，并选择叶轮不同区域的最大应力点来预测其疲劳寿命。本研究对存在铸造缺陷的离心泵叶轮的失效分析具有一定的参考价值，并提出了一些维修建议。

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引用次数: 0