Engineering Failure Analysis最新文献

英文中文

Experimental and numerical study on blast-induced rock damage and fragmentation under low temperatures

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-05 DOI: 10.1016/j.engfailanal.2025.109497

Zilong Zhou , Zhen Wang , Ruishan Cheng , Jiaming Wang

Low temperatures in cold regions have significant effects on rock blasting performance, e.g., blast-induced rock fragmentation. However, very limited study has explored the influences of sub-zero temperatures on blast-induced rock response. The present study employs experimental tests and numerical simulation to examine the damage and fragmentation of rock subjected to blasting under low-temperature conditions. The small-scale blasting tests of rocks at room temperature (i.e., 20 °C) and different low temperatures (i.e., from −10°C to −40°C) are first conducted to examine low temperatures’ effects on blast-induced rock fragmentation by using the three-parameter Generalized Extreme Value (GEV) function and the fractal theory. The findings indicate that the average sizes of blast-induced rock fragments first increase and then fall as the rock temperatures drop from 20 °C to − 40 °C, and the least uniform fragment size distribution is presented at −30 °C. Moreover, the numerical models of a full-scale deep borehole are established to examine the effects of different low-temperature gradient characteristics in rock mass on the damage and fragmentation of rocks caused by blasting. It is observed that the blast-induced damage of the multi-gradient low-temperature rock mass first decreases and then increases with rock depths approaching the ground surface. In addition, it is noted that rock damage and fragmentation induced by blasting can significantly differ with changing multi-gradient low-temperature conditions in a rock mass (e.g., different multi-gradient low-temperature ranges, multi-gradient low-temperature depths in rock mass, and numbers of multi-gradient low-temperature layers). The findings can be used as a reference for fine rock blasting design under low-temperature conditions.

{"title":"Experimental and numerical study on blast-induced rock damage and fragmentation under low temperatures","authors":"Zilong Zhou , Zhen Wang , Ruishan Cheng , Jiaming Wang","doi":"10.1016/j.engfailanal.2025.109497","DOIUrl":"10.1016/j.engfailanal.2025.109497","url":null,"abstract":"<div><div>Low temperatures in cold regions have significant effects on rock blasting performance, e.g., blast-induced rock fragmentation. However, very limited study has explored the influences of sub-zero temperatures on blast-induced rock response. The present study employs experimental tests and numerical simulation to examine the damage and fragmentation of rock subjected to blasting under low-temperature conditions. The small-scale blasting tests of rocks at room temperature (i.e., 20 °C) and different low temperatures (i.e., from −10°C to −40°C) are first conducted to examine low temperatures’ effects on blast-induced rock fragmentation by using the three-parameter Generalized Extreme Value (GEV) function and the fractal theory. The findings indicate that the average sizes of blast-induced rock fragments first increase and then fall as the rock temperatures drop from 20 °C to − 40 °C, and the least uniform fragment size distribution is presented at −30 °C. Moreover, the numerical models of a full-scale deep borehole are established to examine the effects of different low-temperature gradient characteristics in rock mass on the damage and fragmentation of rocks caused by blasting. It is observed that the blast-induced damage of the multi-gradient low-temperature rock mass first decreases and then increases with rock depths approaching the ground surface. In addition, it is noted that rock damage and fragmentation induced by blasting can significantly differ with changing multi-gradient low-temperature conditions in a rock mass (e.g., different multi-gradient low-temperature ranges, multi-gradient low-temperature depths in rock mass, and numbers of multi-gradient low-temperature layers). The findings can be used as a reference for fine rock blasting design under low-temperature conditions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109497"},"PeriodicalIF":4.4,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579345","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

Initiation and propagation mechanism of fish-scale-like fatigue cracks on a U75V quenched rail

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-05 DOI: 10.1016/j.engfailanal.2025.109468

Jihua Liu , Junjie Ou , Jianbin Li , Zihua Yu , Chenggang He , Peng Li , Guiyuan Zhou , Youjie Chen

After rails are returned to service following rehabilitative grinding, severe rolling contact fatigue damage characterized by fish-scale-like oblique cracks occurs on the inner side of the U75VH rail tread. Metallurgical tests were performed on the damaged surfaces and cross-sections to analyse the initiation and propagation mechanisms of the fish-scale-like cracks. The results indicated that the rapid initiation of the microcracks could be attributed mainly to the generation of a thin white etching layer (WEL) during rail grinding. Microcracks initially propagated along the interface of the WEL and matrix, growing horizontally or downward in a “wavy” form and ultimately manifesting as fish-scale-like oblique cracks on the contact surface. Moreover, the WEL was rapidly removed and became much thinner under severe alternating wheel-rail stresses. The longitudinal profile of the fish-scale-like cracks could be divided into “circuitous cracks” and “downward cracks”. The circuitous cracks propagated at a small angle and tended to propagate to the surface in a wave-like pattern, thus resulting in spalling pits. Conversely, the downward cracks tended to propagate deeper into the matrix. Most branch cracks from the main cracks initiated at the peak of the upper crack face. The main propagation mechanism of the branching cracks and the main crack was transcrystalline fracture.

{"title":"Initiation and propagation mechanism of fish-scale-like fatigue cracks on a U75V quenched rail","authors":"Jihua Liu , Junjie Ou , Jianbin Li , Zihua Yu , Chenggang He , Peng Li , Guiyuan Zhou , Youjie Chen","doi":"10.1016/j.engfailanal.2025.109468","DOIUrl":"10.1016/j.engfailanal.2025.109468","url":null,"abstract":"<div><div>After rails are returned to service following rehabilitative grinding, severe rolling contact fatigue damage characterized by fish-scale-like oblique cracks occurs on the inner side of the U75VH rail tread. Metallurgical tests were performed on the damaged surfaces and cross-sections to analyse the initiation and propagation mechanisms of the fish-scale-like cracks. The results indicated that the rapid initiation of the microcracks could be attributed mainly to the generation of a thin white etching layer (WEL) during rail grinding. Microcracks initially propagated along the interface of the WEL and matrix, growing horizontally or downward in a “wavy” form and ultimately manifesting as fish-scale-like oblique cracks on the contact surface. Moreover, the WEL was rapidly removed and became much thinner under severe alternating wheel-rail stresses. The longitudinal profile of the fish-scale-like cracks could be divided into “circuitous cracks” and “downward cracks”. The circuitous cracks propagated at a small angle and tended to propagate to the surface in a wave-like pattern, thus resulting in spalling pits. Conversely, the downward cracks tended to propagate deeper into the matrix. Most branch cracks from the main cracks initiated at the peak of the upper crack face. The main propagation mechanism of the branching cracks and the main crack was transcrystalline fracture.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109468"},"PeriodicalIF":4.4,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579344","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

Study on fatigue crack growth behaviour of Q690D high strength steel with corrosion damage 带腐蚀损伤的 Q690D 高强度钢疲劳裂纹增长行为研究

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-05 DOI: 10.1016/j.engfailanal.2025.109495

Xiaodi Guan , Hongchao Guo , Guoqiang Li , Yanbo Wang , Yuhan Pan

High-performance steel bridges are an important development direction in the field of civil engineering due to their advantages of high load bearing, high durability and efficient construction. However, bridge structures are subjected to long-term corrosive environments when in service, and problems such as corrosion and fatigue damage are difficult to avoid. In this paper, indoor salt spray, dry and wet cyclic accelerated corrosion tests on Q690D high strength steel (HSS) were carried out according to the characteristics of the marine atmospheric region. The fatigue crack growth rate (FCGR) tests and threshold tests were carried out on compact tensile (CT) specimens of two plate thicknesses with different degrees of corrosion damage. And based on the fatigue fracture and surface morphology of corroded CT specimens, the fatigue crack growth (FCG) mechanism of HSS was investigated. The results show that the thickness of the corrosion products deepens with the increase of corrosion time. And the corrosion pits are randomly distributed on the surface of the specimen in clusters, with large and deep pits surrounded by small and shallow pits. The FCGR of Q690D HSS increases significantly with increasing corrosion cycles. The FCGR values at 60 days, 90 days, 120 days and 150 days of corrosion increased by 28.11 %, 35.01 %, 38.87 % and 51.45 % compared with those without corrosion, respectively. And the FCG threshold (FCGT) values decrease approximately linearly with the increase of corrosion damage degree. When the mass loss rate of the specimen increased to 9.195 % and the maximum depth of the corrosion pit was 786 μm, the threshold value was reduced by 31.53 %.

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引用次数: 0

Impact of defects on high cycle fatigue life in wire-arc additive manufactured TC17 alloy

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-05 DOI: 10.1016/j.engfailanal.2025.109480

Banglong Yu , Ping Wang , Peng Zhao , Xiaoguo Song , Man Jae SaGong , Hyoung Seop Kim

Engineering applications for additively manufactured (AM) titanium alloy components are often constrained by suboptimal fatigue properties and high variability in fatigue data due to defects. This study aims to address these limitations by developing a fatigue life prediction model that incorporates the influence of defects in wire arc additive manufacturing (WAAM) TC17 alloy. The microstructure and mechanical properties of WAAM-TC17 were thoroughly characterized. Results revealed that the average α-grains length and width in WAAM-TC17 was significantly smaller, approximately one-twelfth and one-seventeenth of that in Forged-TC17, respectively. The yield strength of the WAAM-TC17 horizontal and vertical specimens was approximately 93% of the Forged-TC17. However, the high-cycle fatigue (HCF) performance of WAAM-TC17 specimens was inferior due to crack initiation dominated by porosity and lack of fusion (LOF) defects. To enhance fatigue life prediction accuracy for defective WAAM-TC17 specimens, a novel parameter K*, derived from the stress concentration factor (K_t) using support vector regressor (SVR) in machine learning (ML), was introduced. The K*-N mean curve demonstrated high predictive accuracy for the HCF life of defective WAAM-TC17 specimens, with a standard deviation (STD) of 0.33.

{"title":"Impact of defects on high cycle fatigue life in wire-arc additive manufactured TC17 alloy","authors":"Banglong Yu , Ping Wang , Peng Zhao , Xiaoguo Song , Man Jae SaGong , Hyoung Seop Kim","doi":"10.1016/j.engfailanal.2025.109480","DOIUrl":"10.1016/j.engfailanal.2025.109480","url":null,"abstract":"<div><div>Engineering applications for additively manufactured (AM) titanium alloy components are often constrained by suboptimal fatigue properties and high variability in fatigue data due to defects. This study aims to address these limitations by developing a fatigue life prediction model that incorporates the influence of defects in wire arc additive manufacturing (WAAM) TC17 alloy. The microstructure and mechanical properties of WAAM-TC17 were thoroughly characterized. Results revealed that the average <em>α</em>-grains length and width in WAAM-TC17 was significantly smaller, approximately one-twelfth and one-seventeenth of that in Forged-TC17, respectively. The yield strength of the WAAM-TC17 horizontal and vertical specimens was approximately 93% of the Forged-TC17. However, the high-cycle fatigue (HCF) performance of WAAM-TC17 specimens was inferior due to crack initiation dominated by porosity and lack of fusion (LOF) defects. To enhance fatigue life prediction accuracy for defective WAAM-TC17 specimens, a novel parameter <em>K*</em>, derived from the stress concentration factor (<em>K<sub>t</sub></em>) using support vector regressor (SVR) in machine learning (ML), was introduced. The <em>K*-N</em> mean curve demonstrated high predictive accuracy for the HCF life of defective WAAM-TC17 specimens, with a standard deviation (STD) of 0.33.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109480"},"PeriodicalIF":4.4,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579682","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

Deformation and failure mechanism of deep-buried tunnel under the action of fault dislocation and application of nonlocal model in numerical simulation research

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-05 DOI: 10.1016/j.engfailanal.2025.109496

Ning Zhang , Hui Zhou , Yang Gao , Yong Zhu , Jingjing Lu , Chengwei Zhao , Guangtan Cheng

Fault dislocation leads to the deformation and failure of deep-buried tunnels, directly affecting the safety of human life and property. In this paper, a physical model test is performed to summarize the deformation and failure mechanism of a deep-buried tunnel subjected to fault dislocation by analyzing tunnel strain, contact pressure, and failure mode. The test is then simulated using a nonlocal model to verify its validity in simulating the response characteristics of tunnel deformation and failure under fault dislocation. The results show that: (1) The deep-buried tunnel undergoes deformation and failure under shear, bending, and compression combined. The shape of the tunnel model after the overall deformation is relatively similar to that of ’S’; (2) The nonlocal model can effectively reproduce the test results and resolve the mesh-dependent problem of numerical simulation results. The research results have guiding significance for the design and construction of deep-buried tunnels that pass through faults. These findings expand the numerical simulation methods for studying the response characteristics of tunnels to fault dislocation.

{"title":"Deformation and failure mechanism of deep-buried tunnel under the action of fault dislocation and application of nonlocal model in numerical simulation research","authors":"Ning Zhang , Hui Zhou , Yang Gao , Yong Zhu , Jingjing Lu , Chengwei Zhao , Guangtan Cheng","doi":"10.1016/j.engfailanal.2025.109496","DOIUrl":"10.1016/j.engfailanal.2025.109496","url":null,"abstract":"<div><div>Fault dislocation leads to the deformation and failure of deep-buried tunnels, directly affecting the safety of human life and property. In this paper, a physical model test is performed to summarize the deformation and failure mechanism of a deep-buried tunnel subjected to fault dislocation by analyzing tunnel strain, contact pressure, and failure mode. The test is then simulated using a nonlocal model to verify its validity in simulating the response characteristics of tunnel deformation and failure under fault dislocation. The results show that: (1) The deep-buried tunnel undergoes deformation and failure under shear, bending, and compression combined. The shape of the tunnel model after the overall deformation is relatively similar to that of ’S’; (2) The nonlocal model can effectively reproduce the test results and resolve the mesh-dependent problem of numerical simulation results. The research results have guiding significance for the design and construction of deep-buried tunnels that pass through faults. These findings expand the numerical simulation methods for studying the response characteristics of tunnels to fault dislocation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109496"},"PeriodicalIF":4.4,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637310","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

3D GPU-accelerated FDEM for fracturing and stability analysis of jointed rock masses due to tunnel excavation

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-05 DOI: 10.1016/j.engfailanal.2025.109498

Jianguo Zhang , Yiming Lei , Yiwei Liu , Man Wang , Quansheng Liu , Chenglei Du , Honggan Yu , Xiquan Zheng

The fracturing and instability of jointed rock masses during tunnel excavation is a complex process involving crack initiation, propagation, and intersection, as well as block spalling, overturning, and extrusion, which poses significant challenges to traditional continuous or discontinuous methods. Leveraging the hybrid Finite-Discrete Element Method (FDEM) and CUDA C/C++ programming model, this study develops a Ytunnel module within the 3D GPU-accelerated FDEM framework. The Ytunnel module incorporates approaches for in-situ stress generation, quasi-static excavation, and detailed rock joint characterization. The effectiveness of the developed method is first validated through two numerical examples: a homogeneous stratum excavation, which demonstrates close alignment with theoretical predictions of stress evolution, and a simulation of the classic URL test tunnel, which accurately captures field-observed damage zone. The failure process of surrounding rock in jointed rock masses caused by tunnel excavation is also investigated. The results reveal that the presence of joints plays a critical role in the fracturing and instability of surrounding rock. The 3D GPU-accelerated FDEM integrated with the Ytunnel module offers a powerful and versatile approach for investigating the complex behaviors of rock masses induced by tunnel excavation.

{"title":"3D GPU-accelerated FDEM for fracturing and stability analysis of jointed rock masses due to tunnel excavation","authors":"Jianguo Zhang , Yiming Lei , Yiwei Liu , Man Wang , Quansheng Liu , Chenglei Du , Honggan Yu , Xiquan Zheng","doi":"10.1016/j.engfailanal.2025.109498","DOIUrl":"10.1016/j.engfailanal.2025.109498","url":null,"abstract":"<div><div>The fracturing and instability of jointed rock masses during tunnel excavation is a complex process involving crack initiation, propagation, and intersection, as well as block spalling, overturning, and extrusion, which poses significant challenges to traditional continuous or discontinuous methods. Leveraging the hybrid Finite-Discrete Element Method (FDEM) and CUDA C/C++ programming model, this study develops a Ytunnel module within the 3D GPU-accelerated FDEM framework. The Ytunnel module incorporates approaches for in-situ stress generation, quasi-static excavation, and detailed rock joint characterization. The effectiveness of the developed method is first validated through two numerical examples: a homogeneous stratum excavation, which demonstrates close alignment with theoretical predictions of stress evolution, and a simulation of the classic URL test tunnel, which accurately captures field-observed damage zone. The failure process of surrounding rock in jointed rock masses caused by tunnel excavation is also investigated. The results reveal that the presence of joints plays a critical role in the fracturing and instability of surrounding rock. The 3D GPU-accelerated FDEM integrated with the Ytunnel module offers a powerful and versatile approach for investigating the complex behaviors of rock masses induced by tunnel excavation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109498"},"PeriodicalIF":4.4,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579681","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 failure behavior of corrosion water supply steel pipes with void around pipes under long-term service load coupling

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-05 DOI: 10.1016/j.engfailanal.2025.109485

Ying Ma , Bin Li , Hongyuan Fang , Xueming Du , Niannian Wang , Danyang Di , Kejie Zhai

Corrosion and void are common defects in the walls and surroundings of water supply steel pipes. Understanding the fatigue failure behavior of steel pipes with combined corrosion and void defects under long-term service loads is essential for assessing their full-service life. This study conducted full-scale fatigue tests on water supply steel pipes with corrosion and void subjected to long-term traffic loads, earth pressure, internal pressure, and groundwater, using an indoor model box testing system. It was observed that the maximum Von Mises strain exhibited slow, rapid, and steady growth as traffic load cycles increased, with a fatigue life of approximately 71.04 million cycles. Subsequently, 3D detailed models of the steel pipe and fluid were established using ABAQUS 6.14–1 and FLUENT 16.0, respectively, and the structural-fluid dynamic coupling was solved through the MpCCI 4.4.2 multiphysics coupling platform. Using the validated FE model, the influence of corrosion length, width, and depth, as well as void position, length, and width, on the fatigue life of the steel pipe was analyzed. Additionally, the longitudinal bending moment and vertical displacement behavior of the pipe at fatigue failure were investigated. It was found that the fatigue life is lowest at the springline, 0.86 and 0.95 times that of the voids at the invert and crown, respectively. As void length, void width, and corrosion length increase from their minimum to maximum design values, the fatigue life of the steel pipe increases by 52%, 45%, and 16%, respectively. However, as corrosion width and depth increase from their minimum to maximum design values, fatigue life decreases by 35% and 54%, respectively. At fatigue failure, the void at the springline results in the smallest longitudinal bending moments and vertical displacements. Both bending moments and displacements increase with increasing void length, width, and corrosion length, while they decrease with increasing corrosion width and depth.

{"title":"Fatigue failure behavior of corrosion water supply steel pipes with void around pipes under long-term service load coupling","authors":"Ying Ma , Bin Li , Hongyuan Fang , Xueming Du , Niannian Wang , Danyang Di , Kejie Zhai","doi":"10.1016/j.engfailanal.2025.109485","DOIUrl":"10.1016/j.engfailanal.2025.109485","url":null,"abstract":"<div><div>Corrosion and void are common defects in the walls and surroundings of water supply steel pipes. Understanding the fatigue failure behavior of steel pipes with combined corrosion and void defects under long-term service loads is essential for assessing their full-service life. This study conducted full-scale fatigue tests on water supply steel pipes with corrosion and void subjected to long-term traffic loads, earth pressure, internal pressure, and groundwater, using an indoor model box testing system. It was observed that the maximum Von Mises strain exhibited slow, rapid, and steady growth as traffic load cycles increased, with a fatigue life of approximately 71.04 million cycles. Subsequently, 3D detailed models of the steel pipe and fluid were established using ABAQUS 6.14–1 and FLUENT 16.0, respectively, and the structural-fluid dynamic coupling was solved through the MpCCI 4.4.2 multiphysics coupling platform. Using the validated FE model, the influence of corrosion length, width, and depth, as well as void position, length, and width, on the fatigue life of the steel pipe was analyzed. Additionally, the longitudinal bending moment and vertical displacement behavior of the pipe at fatigue failure were investigated. It was found that the fatigue life is lowest at the springline, 0.86 and 0.95 times that of the voids at the invert and crown, respectively. As void length, void width, and corrosion length increase from their minimum to maximum design values, the fatigue life of the steel pipe increases by 52%, 45%, and 16%, respectively. However, as corrosion width and depth increase from their minimum to maximum design values, fatigue life decreases by 35% and 54%, respectively. At fatigue failure, the void at the springline results in the smallest longitudinal bending moments and vertical displacements. Both bending moments and displacements increase with increasing void length, width, and corrosion length, while they decrease with increasing corrosion width and depth.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109485"},"PeriodicalIF":4.4,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601406","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 characteristics, failure mechanism and life prediction of copper–aluminum cable joints formed by magnetic pulse crimping

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-04 DOI: 10.1016/j.engfailanal.2025.109483

Shaoluo Wang , Xiangyu Gao , Zhiquan Huang , Hao Jiang , Guangyao Li , Junjia Cui

Magnetic pulse crimping process has significant potential for high-voltage cable joint manufacturing due to its green, eco-friendly, efficient, and reliable advantages. In this paper, the fatigue characteristics and fracture behaviors of Cu-Al dissimilar cable joints prepared by magnetic pulse crimping (MPC) and hydraulic crimping (HC) were explored and compared. The fatigue life prediction models for the two cable joints at different reliability levels were developed. The contact resistance change features, crack propagation laws and fatigue failure mechanisms of cable joints were revealed. Results showed that the failure modes of cable joints at different stress levels could be divided into Al harness fracture (S_M ≥ 45.7 MPa), Cu terminal fracture (S_M < 34.3 MPa), and mixed fracture of the two (S_M = 34.3 MPa). As the stress level decreased, the fatigue life of cable joints gradually increased, and the failure mode gradually transitioned from Al harness fracture to Cu terminal fracture. The contact resistance of MPC and HC cable joints presented opposite changes during the fatigue process. Fretting wear at the Al-Cu contact generated Al₂O₃ particles. The initial fatigue cracks mainly initiated at the surface damage of Al harness in the crimping area and at the intersection of the tube end and the plate end on the upper surface of Cu terminal. Because there were significant stress concentrations at these two locations. The fatigue fractures all had typical crack initiation zones, crack propagation zones and instantaneous fracture zones.

{"title":"Fatigue characteristics, failure mechanism and life prediction of copper–aluminum cable joints formed by magnetic pulse crimping","authors":"Shaoluo Wang , Xiangyu Gao , Zhiquan Huang , Hao Jiang , Guangyao Li , Junjia Cui","doi":"10.1016/j.engfailanal.2025.109483","DOIUrl":"10.1016/j.engfailanal.2025.109483","url":null,"abstract":"<div><div>Magnetic pulse crimping process has significant potential for high-voltage cable joint manufacturing due to its green, eco-friendly, efficient, and reliable advantages. In this paper, the fatigue characteristics and fracture behaviors of Cu-Al dissimilar cable joints prepared by magnetic pulse crimping (MPC) and hydraulic crimping (HC) were explored and compared. The fatigue life prediction models for the two cable joints at different reliability levels were developed. The contact resistance change features, crack propagation laws and fatigue failure mechanisms of cable joints were revealed. Results showed that the failure modes of cable joints at different stress levels could be divided into Al harness fracture (<em>S</em><sub>M</sub> ≥ 45.7 MPa), Cu terminal fracture (<em>S</em><sub>M</sub> < 34.3 MPa), and mixed fracture of the two (<em>S</em><sub>M</sub> = 34.3 MPa). As the stress level decreased, the fatigue life of cable joints gradually increased, and the failure mode gradually transitioned from Al harness fracture to Cu terminal fracture. The contact resistance of MPC and HC cable joints presented opposite changes during the fatigue process. Fretting wear at the Al-Cu contact generated Al<sub>2</sub>O<sub>3</sub> particles. The initial fatigue cracks mainly initiated at the surface damage of Al harness in the crimping area and at the intersection of the tube end and the plate end on the upper surface of Cu terminal. Because there were significant stress concentrations at these two locations. The fatigue fractures all had typical crack initiation zones, crack propagation zones and instantaneous fracture zones.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109483"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552159","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 of delayed cracks in heavy forged steel rolls for reduction gears

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-04 DOI: 10.1016/j.engfailanal.2025.109481

Ihho Park, Won-Jon Yang, Jae Hoon Jang

Hydrogen-induced cracking in heavy forged steel rolls was investigated to understand the damage mechanisms in cracked roller products. Cracks, initially observed several weeks after manufacturing, were found in the central band (A-type segregation region) of the roll, characterized by hairline cracks several millimeters in size. Microstructural analysis revealed an increased number of MnS inclusions at the crack sites, with these inclusions being larger in size and more abundant compared to other regions of the roll. Thermodynamic calculations and hydrogen pressure estimations were performed to model the conditions under which cracks propagate, particularly when hydrogen accumulates at the interface between MnS inclusions and the surrounding matrix. When the sulfur content was 0.003 wt%, cracks were predicted to occur when MnS inclusions exceeded approximately 1.3 µm in size.

引用次数: 0

Fatigue prediction of wind turbine tower considering the effect of high-tension bolt failure

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-04 DOI: 10.1016/j.engfailanal.2025.109494

Yuka Kikuchi, Takeshi Ishihara

In this study, an accident at Taikoyama wind farm is investigated by the fatigue analysis of high-tension bolts and tower. Firstly, a sophisticated aeroelastic model is proposed by identifying the structural and control parameters and validated with the measured tower base bending moment. The predicted bending moment at the tower top shows that the tensile stress occurs at the downwind side of tower due to the eccentricity of the centre of gravity of rotor and nacelle. The bolt axial force is then predicted using the finite element model of the tower top with consideration of effects of ball bearings, yaw breaks and pinion gear. The predicted bolt fatigue life is about three months when the residual bolt axial force is less than 30 %, which matches the maintenance record. Finally, the stress of the tower shell is investigated by a sophisticated FEM model. It is found that the tensile stress is generated inside of the tower shell due to the leverage effect. The relationship between the local stress and the nominal stress shows the nonlinearity and the local stress in the case with damaged bolts is three times larger than that in the case with intact bolts. The predicted fatigue life of the tower favourably agrees with the observation.

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引用次数: 0

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