Engineering Failure Analysis最新文献_第2页

Research on fatigue crack propagation and fracture failure analysis of piston rod

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-11 DOI: 10.1016/j.engfailanal.2025.109523

Zhen Chen , Nengpeng Chen , Qiaomu Wang , Qingjie Ran , Chaocheng Wei , Jun Tang , Junhai Long , Yuling Zhang

The reciprocating compressors in underground gas storage (UGS) run under high temperature and high pressure for a long time, which leads to the piston rod bearing complex alternating load, easy to generate fatigue cracks and spread, and eventually lead to fracture failure, which seriously affects the safe operation of UGS. In this paper, the causes of piston rod fracture failure under actual operating conditions are studied by numerical simulation and test. Firstly, a finite element model is established based on the actual cyclic load of the piston rod, which is used as the boundary condition for crack propagation analysis. The crack propagation model is established by adaptive meshing method, and the stress intensity factor leading to crack propagation is determined by M−integral method. According to the fracture toughness of the piston rod material, the fracture failure occurs when the crack propagation length is 29.599 mm, and the fatigue crack propagation life extends with the decrease of the speed or the increase of the exhaust pressure. Secondly, the fracture morphology of the piston rod is analyzed, and the fracture type is determined to be fatigue fracture, and the crack source starts at the transition corner of the surface, which confirms the accuracy of the numerical simulation results. Long-term alternating load leads to stress concentration and initial crack. Metallographic analysis shows that excessive inclusion, abnormal organization and the presence of Se element are the main factors leading to fatigue fracture of the piston rod. The research results provide valuable insights and theoretical basis for fatigue failure problem and fatigue optimization design of piston rod, and have practical engineering guidance significance.

{"title":"Research on fatigue crack propagation and fracture failure analysis of piston rod","authors":"Zhen Chen , Nengpeng Chen , Qiaomu Wang , Qingjie Ran , Chaocheng Wei , Jun Tang , Junhai Long , Yuling Zhang","doi":"10.1016/j.engfailanal.2025.109523","DOIUrl":"10.1016/j.engfailanal.2025.109523","url":null,"abstract":"<div><div>The reciprocating compressors in underground gas storage (UGS) run under high temperature and high pressure for a long time, which leads to the piston rod bearing complex alternating load, easy to generate fatigue cracks and spread, and eventually lead to fracture failure, which seriously affects the safe operation of UGS. In this paper, the causes of piston rod fracture failure under actual operating conditions are studied by numerical simulation and test. Firstly, a finite element model is established based on the actual cyclic load of the piston rod, which is used as the boundary condition for crack propagation analysis. The crack propagation model is established by adaptive meshing method, and the stress intensity factor leading to crack propagation is determined by M−integral method. According to the fracture toughness of the piston rod material, the fracture failure occurs when the crack propagation length is 29.599 mm, and the fatigue crack propagation life extends with the decrease of the speed or the increase of the exhaust pressure. Secondly, the fracture morphology of the piston rod is analyzed, and the fracture type is determined to be fatigue fracture, and the crack source starts at the transition corner of the surface, which confirms the accuracy of the numerical simulation results. Long-term alternating load leads to stress concentration and initial crack. Metallographic analysis shows that excessive inclusion, abnormal organization and the presence of Se element are the main factors leading to fatigue fracture of the piston rod. The research results provide valuable insights and theoretical basis for fatigue failure problem and fatigue optimization design of piston rod, and have practical engineering guidance significance.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109523"},"PeriodicalIF":4.4,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628561","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

Investigation on static and fatigue performance of CFRP/Al-alloy interference bolted joint considering the influence of hole-axis error

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-10 DOI: 10.1016/j.engfailanal.2025.109516

Caoyang Wang , Hui Cheng , Wenlong Hu , Yuan Li , Kaifu Zhang , Yi Cheng

Hole-axis error is one of the normal manufacturing errors during aircraft assembly due to non-uniform deformation caused by drilling, assembly force, and post-assembly positioning. This paper investigated the influence of hole-axis error on the static and fatigue performance of CFRP/Al-alloy bolted joints. Experimental investigations were carried out to evaluate the impact of hole-axis error (0.00 mm, 0.05 mm, 0.10 mm, and 0.15 mm) on static and fatigue performance of CFRP/Al-alloy interference bolted joints. The variation of hole-axis error within a certain range has a slight influence on the ultimate tensile strength of the joint. At the same time, the fatigue life increases at first and then decreases with the increase in the value of the hole-axis error. The hole-axis error introduces a pre-loading state of the bolted joint, which makes the material damaged in advance and decreases the structure stiffness. A scanning electron microscope (SEM) was used to observe the damage of holes. A modified fatigue life model was proposed to predict the fatigue life of CFRP/Al-alloy bolted joints with different hole-axis errors. A rational threshold for hole-axis error can be established, which is less than 0.15 mm (3 %). The results of this paper can provide corresponding guidance for the tolerance design of bolted joints with hole-axis error.

{"title":"Investigation on static and fatigue performance of CFRP/Al-alloy interference bolted joint considering the influence of hole-axis error","authors":"Caoyang Wang , Hui Cheng , Wenlong Hu , Yuan Li , Kaifu Zhang , Yi Cheng","doi":"10.1016/j.engfailanal.2025.109516","DOIUrl":"10.1016/j.engfailanal.2025.109516","url":null,"abstract":"<div><div>Hole-axis error is one of the normal manufacturing errors during aircraft assembly due to non-uniform deformation caused by drilling, assembly force, and post-assembly positioning. This paper investigated the influence of hole-axis error on the static and fatigue performance of CFRP/Al-alloy bolted joints. Experimental investigations were carried out to evaluate the impact of hole-axis error (0.00 mm, 0.05 mm, 0.10 mm, and 0.15 mm) on static and fatigue performance of CFRP/Al-alloy interference bolted joints. The variation of hole-axis error within a certain range has a slight influence on the ultimate tensile strength of the joint. At the same time, the fatigue life increases at first and then decreases with the increase in the value of the hole-axis error. The hole-axis error introduces a pre-loading state of the bolted joint, which makes the material damaged in advance and decreases the structure stiffness. A scanning electron microscope (SEM) was used to observe the damage of holes. A modified fatigue life model was proposed to predict the fatigue life of CFRP/Al-alloy bolted joints with different hole-axis errors. A rational threshold for hole-axis error can be established, which is less than 0.15 mm (3 %). The results of this paper can provide corresponding guidance for the tolerance design of bolted joints with hole-axis error.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109516"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637313","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

Optimizing hot tearing susceptibility of Mg-1Ca alloy by pulsed magnetic fields: Experimental investigation and numerical simulation

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-10 DOI: 10.1016/j.engfailanal.2025.109518

Xin Guo , Yi Liu , Hua Zhao , Jiangfeng Song , Jinge Liao , Xiaohui Feng , Bin Jiang , Yuansheng Yang

In this paper, the influence of pulsed magnetic fields (PMF) with different voltages (0 V, 50 V, 100 V, and 150 V) on the hot tearing susceptibility (HTS) of Mg-1Ca alloy was investigated, hot tearing experiments were carried out with a constraint rod casting (CRC) mold, and COMSOL simulations of the solidification process were performed. The experimental results showed that the HTS of the alloy decreased with increasing PMF voltage, and the alloy exhibited the lowest HTS at a PMF voltage of 150 V. The area of hot tears in hot spots was reduced from a complete fracture (∞) to 0.21 mm², and the cracking susceptibility coefficient (CSC_t) value decreased from 1.83 to 1.58. The application of PMF accelerates the passage through the susceptibility temperature range of hot tearing. Combined with the simulation results, it is shown that with the increase of PMF intensity, the forced convection of induced melt is enhanced, which leads to the breakage or separation of primary brittle dendrites and makes the grains more refined. It not only increases the tensile stress required for liquid film separation but also reduces the shrinkage strain acting on the grain boundary per unit. In addition, the electromagnetic force forcibly drives the melt to flow, which increases the flow velocity of the melt, thus enhancing the feeding ability of the alloy. Finally, the HTS of Mg-1Ca alloy was obviously optimized.

{"title":"Optimizing hot tearing susceptibility of Mg-1Ca alloy by pulsed magnetic fields: Experimental investigation and numerical simulation","authors":"Xin Guo , Yi Liu , Hua Zhao , Jiangfeng Song , Jinge Liao , Xiaohui Feng , Bin Jiang , Yuansheng Yang","doi":"10.1016/j.engfailanal.2025.109518","DOIUrl":"10.1016/j.engfailanal.2025.109518","url":null,"abstract":"<div><div>In this paper, the influence of pulsed magnetic fields (PMF) with different voltages (0 V, 50 V, 100 V, and 150 V) on the hot tearing susceptibility (HTS) of Mg-1Ca alloy was investigated, hot tearing experiments were carried out with a constraint rod casting (CRC) mold, and COMSOL simulations of the solidification process were performed. The experimental results showed that the HTS of the alloy decreased with increasing PMF voltage, and the alloy exhibited the lowest HTS at a PMF voltage of 150 V. The area of hot tears in hot spots was reduced from a complete fracture (∞) to 0.21 mm<sup>2</sup>, and the cracking susceptibility coefficient (<em>CSC</em><sub>t</sub>) value decreased from 1.83 to 1.58. The application of PMF accelerates the passage through the susceptibility temperature range of hot tearing. Combined with the simulation results, it is shown that with the increase of PMF intensity, the forced convection of induced melt is enhanced, which leads to the breakage or separation of primary brittle dendrites and makes the grains more refined. It not only increases the tensile stress required for liquid film separation but also reduces the shrinkage strain acting on the grain boundary per unit. In addition, the electromagnetic force forcibly drives the melt to flow, which increases the flow velocity of the melt, thus enhancing the feeding ability of the alloy. Finally, the HTS of Mg-1Ca alloy was obviously optimized.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109518"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143631912","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

Failure analysis of stress corrosion cracking of 316L stainless steel bend pipe in the atmospheric tower

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-10 DOI: 10.1016/j.engfailanal.2025.109519

Lei Chen , Hejin Li , Bingtao Qin , Lida Wang , Piji Zhang , Wen Sun , Hua Wang , Zhengqing Yang , Guichang Liu

The top circulation system of the atmospheric tower maintains the fractionation balance inside the tower by refluxing and condensing the liquid. During operation, cracking and leakage occurred in the 316L stainless steel elbow of the recirculation line. A detailed failure analysis was conducted through experimental testing, along with stress analysis and fluid flow simulations. The results showed that a small amount of water in the gasoline tends to accumulate on the outer side of the elbow under the effects of by centrifugal forces, creating a chloride and sulfur corrosive environment. The inner wall of the elbow underwent localized pitting corrosion due to the combined effects of welding thermal influence and chloride ion corrosion, resulting in the formation of numerous corrosion pits. Under the influence of external tensile stress and welding residual stress, these corrosion pits served as crack initiation sites and gradually propagated, ultimately leading to leakage failure. This failure was the result of the combined action of multiple factors, including welding residual stress, corrosive environment, and external loading. Based on the failure analysis, a series of targeted protective measures were proposed as well.

{"title":"Failure analysis of stress corrosion cracking of 316L stainless steel bend pipe in the atmospheric tower","authors":"Lei Chen , Hejin Li , Bingtao Qin , Lida Wang , Piji Zhang , Wen Sun , Hua Wang , Zhengqing Yang , Guichang Liu","doi":"10.1016/j.engfailanal.2025.109519","DOIUrl":"10.1016/j.engfailanal.2025.109519","url":null,"abstract":"<div><div>The top circulation system of the atmospheric tower maintains the fractionation balance inside the tower by refluxing and condensing the liquid. During operation, cracking and leakage occurred in the 316L stainless steel elbow of the recirculation line. A detailed failure analysis was conducted through experimental testing, along with stress analysis and fluid flow simulations. The results showed that a small amount of water in the gasoline tends to accumulate on the outer side of the elbow under the effects of by centrifugal forces, creating a chloride and sulfur corrosive environment. The inner wall of the elbow underwent localized pitting corrosion due to the combined effects of welding thermal influence and chloride ion corrosion, resulting in the formation of numerous corrosion pits. Under the influence of external tensile stress and welding residual stress, these corrosion pits served as crack initiation sites and gradually propagated, ultimately leading to leakage failure. This failure was the result of the combined action of multiple factors, including welding residual stress, corrosive environment, and external loading. Based on the failure analysis, a series of targeted protective measures were proposed as well.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109519"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611333","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

Multifactorial prediction of corrosion fatigue crack growth in aluminum alloys using physics-informed neural networks

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-10 DOI: 10.1016/j.engfailanal.2025.109521

Tianhao Huang , Xueyuan Li , Yongzhen Zhang , Leijiang Yao , Tao Zhang

In-service corrosion fatigue cracking in aluminum alloy structural components poses a significant threat to the structural integrity of aircraft, making accurate crack propagation prediction essential for both safety and maintenance planning. Traditional machine learning models, such as Random Forest, Extreme Gradient Boosting (XGBoost), and Artificial Neural Network (ANN), rely primarily on data-driven methods and often neglect the underlying physical mechanisms, resulting in reduced prediction accuracy in complex environments. To overcome this limitation, physics-informed neural network (PINN) is used, which integrate physical laws (the Walker crack growth model) with data-driven learning. This hybrid approach effectively captures critical factors that influence crack propagation, such as initial crack length, stress ratio, and environmental conditions (e.g., pH, temperature, and chloride ion concentration). By embedding physical knowledge into the network, PINN significantly improves both the accuracy and generalizability of crack growth prediction. Experimental validation on various aluminum alloys, including 2024, 7075, and LY12, demonstrates that PINN outperforms traditional models, achieving higher prediction accuracy and faster convergence. The study underscores the potential of PINN for crack growth prediction, advancing fatigue life prediction and contributing to improved safety and durability of aircraft components.

{"title":"Multifactorial prediction of corrosion fatigue crack growth in aluminum alloys using physics-informed neural networks","authors":"Tianhao Huang , Xueyuan Li , Yongzhen Zhang , Leijiang Yao , Tao Zhang","doi":"10.1016/j.engfailanal.2025.109521","DOIUrl":"10.1016/j.engfailanal.2025.109521","url":null,"abstract":"<div><div>In-service corrosion fatigue cracking in aluminum alloy structural components poses a significant threat to the structural integrity of aircraft, making accurate crack propagation prediction essential for both safety and maintenance planning. Traditional machine learning models, such as Random Forest, Extreme Gradient Boosting (XGBoost), and Artificial Neural Network (ANN), rely primarily on data-driven methods and often neglect the underlying physical mechanisms, resulting in reduced prediction accuracy in complex environments. To overcome this limitation, physics-informed neural network (PINN) is used, which integrate physical laws (the Walker crack growth model) with data-driven learning. This hybrid approach effectively captures critical factors that influence crack propagation, such as initial crack length, stress ratio, and environmental conditions (e.g., pH, temperature, and chloride ion concentration). By embedding physical knowledge into the network, PINN significantly improves both the accuracy and generalizability of crack growth prediction. Experimental validation on various aluminum alloys, including 2024, 7075, and LY12, demonstrates that PINN outperforms traditional models, achieving higher prediction accuracy and faster convergence. The study underscores the potential of PINN for crack growth prediction, advancing fatigue life prediction and contributing to improved safety and durability of aircraft components.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109521"},"PeriodicalIF":4.4,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611336","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

Failure analysis by keyway stress concentration of a pickling decoiler machine output shaft

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-09 DOI: 10.1016/j.engfailanal.2025.109515

Pedro R. da Costa , M. Freitas

In July 2021, an intervention and fracture analysis were conducted following the failure of a shaft in a pickling decoiler box machine. Mechanical hardness and chemical composition measurements, performed in the owner’s laboratories, revealed that the shaft was made of low-alloy steel containing chromium (Cr) and molybdenum (Mo), similar to 42CrMo4 (DIN standard) or 4140 (AISI standard), quenched and tempered. Close inspection of the fracture surface indicated that failure originated from rotating bending efforts. The combination of the rotary bending stresses with two stress concentration effects − one due to a keyway and another due to a diameter transition −resulted in localized stresses exceeding the material’s estimated fatigue endurance. The resulting high local stress caused multiple fatigue crack initiation points along the shaft perimeter, leading to progressive crack growth and eventual failure. Finite element analysis characterized the two stress concentration factors, revealing that the keyway had the most significant impact. To address the issue, an in-depth analysis of the keyway’s bending stress concentration factor and the associated stress distribution was conducted, culminating in the proposal of a new keyway location and geometry.

{"title":"Failure analysis by keyway stress concentration of a pickling decoiler machine output shaft","authors":"Pedro R. da Costa , M. Freitas","doi":"10.1016/j.engfailanal.2025.109515","DOIUrl":"10.1016/j.engfailanal.2025.109515","url":null,"abstract":"<div><div>In July 2021, an intervention and fracture analysis were conducted following the failure of a shaft in a pickling decoiler box machine. Mechanical hardness and chemical composition measurements, performed in the owner’s laboratories, revealed that the shaft was made of low-alloy steel containing chromium (Cr) and molybdenum (Mo), similar to 42CrMo4 (DIN standard) or 4140 (AISI standard), quenched and tempered. Close inspection of the fracture surface indicated that failure originated from rotating bending efforts. The combination of the rotary bending stresses with two stress concentration effects − one due to a keyway and another due to a diameter transition −resulted in localized stresses exceeding the material’s estimated fatigue endurance. The resulting high local stress caused multiple fatigue crack initiation points along the shaft perimeter, leading to progressive crack growth and eventual failure. Finite element analysis characterized the two stress concentration factors, revealing that the keyway had the most significant impact. To address the issue, an in-depth analysis of the keyway’s bending stress concentration factor and the associated stress distribution was conducted, culminating in the proposal of a new keyway location and geometry.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109515"},"PeriodicalIF":4.4,"publicationDate":"2025-03-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592037","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

Fatigue fracture behavior under thermal cyclic loads: Experimental methods, physical regularities, and damage mechanisms 热循环载荷下的疲劳断裂行为：实验方法、物理规律和损伤机制

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-09 DOI: 10.1016/j.engfailanal.2025.109508

Chenyu Du , Haitao Cui , Hongjian Zhang

Thermal fatigue and creep-thermal fatigue are two typical fatigue fracture behaviors under thermal cyclic loads. This study focuses on three aspects. i. Experimental methods. A thermal cyclic experimental method suitable for thin-walled structures with holes was developed, and a tubular specimen with test holes was designed. By comparing different test hole configurations, it was found that the conical hole specimen shows the best performance in both crack growth and observation. ii. Physical regularities. Experiments were conducted with temperature range, mean temperature, and high-temperature hold time as the control variables. The influence patterns of these variables were empirically explained. The data demonstrated that the temperature range and high-temperature hold time are the main factors accelerating crack propagation. The increase in mean temperature reduced the fatigue life, but the effect was relatively weak. iii. Damage mechanisms. Microstructural observation and elemental analysis were conducted, and the damage mechanisms for both behaviors were summarized. The initiation and propagation of thermal fatigue cracks are primarily governed by fatigue behavior, with transgranular fracture as the dominant damage mode. Crack initiation in creep-thermal fatigue is still dominated by fatigue behavior. However, crack propagation is driven by the combined effects of creep, fatigue, and oxidation, resulting in intergranular fracture as the primary damage mode.

{"title":"Fatigue fracture behavior under thermal cyclic loads: Experimental methods, physical regularities, and damage mechanisms","authors":"Chenyu Du , Haitao Cui , Hongjian Zhang","doi":"10.1016/j.engfailanal.2025.109508","DOIUrl":"10.1016/j.engfailanal.2025.109508","url":null,"abstract":"<div><div>Thermal fatigue and creep-thermal fatigue are two typical fatigue fracture behaviors under thermal cyclic loads. This study focuses on three aspects. <em>i. Experimental methods.</em> A thermal cyclic experimental method suitable for thin-walled structures with holes was developed, and a tubular specimen with test holes was designed. By comparing different test hole configurations, it was found that the conical hole specimen shows the best performance in both crack growth and observation. <em>ii. Physical regularities.</em> Experiments were conducted with temperature range, mean temperature, and high-temperature hold time as the control variables. The influence patterns of these variables were empirically explained. The data demonstrated that the temperature range and high-temperature hold time are the main factors accelerating crack propagation. The increase in mean temperature reduced the fatigue life, but the effect was relatively weak. <em>iii</em>. <em>Damage mechanisms.</em> Microstructural observation and elemental analysis were conducted, and the damage mechanisms for both behaviors were summarized. The initiation and propagation of thermal fatigue cracks are primarily governed by fatigue behavior, with transgranular fracture as the dominant damage mode. Crack initiation in creep-thermal fatigue is still dominated by fatigue behavior. However, crack propagation is driven by the combined effects of creep, fatigue, and oxidation, resulting in intergranular fracture as the primary damage mode.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109508"},"PeriodicalIF":4.4,"publicationDate":"2025-03-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592034","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

Data-driven investigation of elastoplastic and failure analysis of additively manufactured parts under bending conditions

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-09 DOI: 10.1016/j.engfailanal.2025.109505

Majid Shafaie , Mohsen Sarparast , Hongyan Zhang

This study presents an advanced investigation the elastoplastic and failure behavior under bending condition applied to a Ti-6Al-4 V alloy part fabricated by Laser Powder Bed Fusion (LPBF) techniques. The objective is to develop a robust framework to accurately predict the material behavior of Ti-6Al-4 V alloy under bending loads by integrating the Finite Element Method (FEM), Deep Neural Networks (DNN), and Genetic Algorithms (GA) as an intelligent data-driven system. The prediction model incorporates many input components, including elastic modulus, Poisson’s ratio, Swift hardening model parameters, and modified GTN fracture model coefficients. The DNNs are trained using data generated from FEM simulations. Model evaluation is performed through k-fold cross-validation, ensuring robust performance assessment. GA are employed to optimize the coefficients of the elastic, plastic, and fracture models, minimizing the root-square normalized error (RSNE) between simulation results and experimental data. If the required error threshold is not achieved in an iteration, the process continues automatically, incorporating new data until the desired accuracy is reached. The findings demonstrate a successful characterization of elastic, plastic, and fracture-related properties, highlighting the capability of the proposed methodology to accurately predict the material behavior of components manufactured by various techniques under different conditions. This approach highlights the potential for extending the methodology to other materials and manufacturing processes, enabling precise prediction of material behavior in diverse applications.

{"title":"Data-driven investigation of elastoplastic and failure analysis of additively manufactured parts under bending conditions","authors":"Majid Shafaie , Mohsen Sarparast , Hongyan Zhang","doi":"10.1016/j.engfailanal.2025.109505","DOIUrl":"10.1016/j.engfailanal.2025.109505","url":null,"abstract":"<div><div>This study presents an advanced investigation the elastoplastic and failure behavior under bending condition applied to a Ti-6Al-4 V alloy part fabricated by Laser Powder Bed Fusion (LPBF) techniques. The objective is to develop a robust framework to accurately predict the material behavior of Ti-6Al-4 V alloy under bending loads by integrating the Finite Element Method (FEM), Deep Neural Networks (DNN), and Genetic Algorithms (GA) as an intelligent data-driven system. The prediction model incorporates many input components, including elastic modulus, Poisson’s ratio, Swift hardening model parameters, and modified GTN fracture model coefficients. The DNNs are trained using data generated from FEM simulations. Model evaluation is performed through k-fold cross-validation, ensuring robust performance assessment. GA are employed to optimize the coefficients of the elastic, plastic, and fracture models, minimizing the root-square normalized error (RSNE) between simulation results and experimental data. If the required error threshold is not achieved in an iteration, the process continues automatically, incorporating new data until the desired accuracy is reached. The findings demonstrate a successful characterization of elastic, plastic, and fracture-related properties, highlighting the capability of the proposed methodology to accurately predict the material behavior of components manufactured by various techniques under different conditions. This approach highlights the potential for extending the methodology to other materials and manufacturing processes, enabling precise prediction of material behavior in diverse applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109505"},"PeriodicalIF":4.4,"publicationDate":"2025-03-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143611329","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Microstructural investigation into the damage mechanism of short pitch rail corrugation

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-08 DOI: 10.1016/j.engfailanal.2025.109512

Pan Zhang, Shaoguang Li, Fang Ren, Omid Hajizad, Rolf Dollevoet, Zili Li

Short pitch corrugation is a typical rail defect that lacks a thorough understanding and adequate root-cause solutions. This paper aims to identify the damage mechanism of short pitch corrugation through a microstructural analysis of a field rail sample. This sample made of R260Mn pearlitic steel was taken from a straight section of the Dutch railway network, and its geometry and surface hardness variation along the corrugation were measured and analyzed. Eleven specimens, including both corrugated and non-corrugated zones, were sectioned from the rail sample and continuously examined using light optical microscopy, scanning electron microscopy and micro-hardness testing. The results indicate that the corrugation damage mechanism can be categorized into three stages: (1) pre-corrugation, characterized by uniform wear and plastic deformation; (2) corrugation initiation, dominated by differential wear; and (3) corrugation growth, involving both differential wear and plastic deformation accumulation. The initiation and growth of corrugation both contribute to an inhomogeneous distribution of plastic deformation layer (PDL) in the rail subsurface, which follows an approximately sinusoidal pattern, matching the corrugation geometry in both wavelength and phase. Consequently, the hardness also varies in phase with the corrugation geometry, with higher hardness values at corrugation peaks. In the non-corrugation zone, the PDL and hardness show relatively small and irregular fluctuations. This study also provides meaningful insights into rail grinding, suggesting that grinding should account for differential PDL thickness to prevent corrugation reoccurrence due to subsurface material inhomogeneity.

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引用次数: 0

Fatigue behaviour and S-N curve prediction of additively manufactured Inconel 718 using Self-Heating and Energy-Based methods

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-08 DOI: 10.1016/j.engfailanal.2025.109507

Martin Matušů , Bastian Roidl , Simon Amann , Jakub Rosenthal , Ivana Zetková , Miroslav Zetek

Inconel 718, a nickel-based superalloy, is extensively used in high-performance applications such as gas turbines, aerospace, and the nuclear and oil industries due to its exceptional fatigue resistance, corrosion resistance, and mechanical stability across a broad temperature range (−252 °C to over 700 °C). Its weldability and high-strength properties make it suitable for additive manufacturing (AM), particularly laser powder bed fusion (L-PBF). However, the dynamic properties of AM Inconel 718, influenced by surface roughness and microstructural variations, require thorough investigation. This study evaluates the mechanical properties of AM Inconel 718 in two build orientations produced using an EOS M290 printer. Static tests and hardness measurements were conducted to establish baseline properties. The fatigue behaviour was analysed using traditional S-N curve testing alongside a self-heating (S-H) methodology adapted from previous studies on AMed AlSi10Mg. The S-H method, focusing on temperature evolution during cyclic loading, was used to estimate the fatigue limit (FL) and S-N curve predictions. The LinExp method provided slightly conservative FL estimates, which served as lower thresholds for Fargione’s energy-based S-N curve model. Only two specimens per orientation were used, demonstrating its efficiency and resource-saving potential. This work underscores the viability of integrating innovative fatigue analysis techniques with traditional methods to optimize the design and evaluation of additively manufactured components.

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引用次数: 0