Engineering Failure Analysis最新文献

英文中文

Investigating hunting stability failure in a high-speed locomotive: A comparative analysis of evaluation methods for typical worn wheel treads

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.2025.109482

Hu Li , Tong Tan , Sebastian Stichel , Yuan Yao

Hunting stability is a critical factor affecting high-speed locomotives dynamic performance, inherently connected to wheel-rail contact geometry. Tread wear typically increases the nonlinearities in the contact geometry, causing stability disparities. Previous studies on stability have often overlooked these nonlinear aspects, which can be captured by the equivalent conicity function. In this study, the equivalent conicity functions of worn wheel treads are systematically categorized into six distinct classes. This classification allows for a comprehensive evaluation of their respective influence on hunting stability failure, enabling the analysis of stability characteristics of typical worn wheel treads. The limited research available on three-axle bogies motivate the selection of a locomotive equipped with such bogies as the basis for framework, aiming to bridge the gap in existing literature. Based on different stability evaluation methods, theoretical, small-amplitude hunting, and engineering critical speeds have been determined. The observed differences in different critical speeds from the perspective of equivalent conicity function are elucidated. The results show that a high equivalent conicity at small displacement can significantly reduce the theoretical critical speed, and therefore, the engineering critical speed is recommended as a criterion for stability assessment and optimization. Moreover, the Driving Energy Loss Ratio (DELR), a metric assessing both primary and secondary hunting stability, is developed to evaluate the stability of self-excited vibrations. This research provides guidance for the evaluation and optimization of railway vehicle stability.

{"title":"Investigating hunting stability failure in a high-speed locomotive: A comparative analysis of evaluation methods for typical worn wheel treads","authors":"Hu Li , Tong Tan , Sebastian Stichel , Yuan Yao","doi":"10.1016/j.engfailanal.2025.109482","DOIUrl":"10.1016/j.engfailanal.2025.109482","url":null,"abstract":"<div><div>Hunting stability is a critical factor affecting high-speed locomotives dynamic performance, inherently connected to wheel-rail contact geometry. Tread wear typically increases the nonlinearities in the contact geometry, causing stability disparities. Previous studies on stability have often overlooked these nonlinear aspects, which can be captured by the equivalent conicity function. In this study, the equivalent conicity functions of worn wheel treads are systematically categorized into six distinct classes. This classification allows for a comprehensive evaluation of their respective influence on hunting stability failure, enabling the analysis of stability characteristics of typical worn wheel treads. The limited research available on three-axle bogies motivate the selection of a locomotive equipped with such bogies as the basis for framework, aiming to bridge the gap in existing literature. Based on different stability evaluation methods, theoretical, small-amplitude hunting, and engineering critical speeds have been determined. The observed differences in different critical speeds from the perspective of equivalent conicity function are elucidated. The results show that a high equivalent conicity at small displacement can significantly reduce the theoretical critical speed, and therefore, the engineering critical speed is recommended as a criterion for stability assessment and optimization. Moreover, the Driving Energy Loss Ratio (DELR), a metric assessing both primary and secondary hunting stability, is developed to evaluate the stability of self-excited vibrations. This research provides guidance for the evaluation and optimization of railway vehicle stability.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109482"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561682","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 behaviours of steel/aluminium threaded connections under impact fatigue

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.2025.109473

Chenxu Zhang , Ruoheng Sun , Jianping Yin , Yilun Hu , Qingbo Dou , Zhongbin Tang , Yinggang Miao , Yulong Li

Threaded connections work as essential components in engineering structures, covering multiple industries such as aerospace and construction. However, they are frequently exposed to complex loadings of dynamic and impact loads, which even result in unexpected fatigue failure. In this study, we modify Hopkinson tension bar technique by guiding stress wave reflection, to achieve controllable cyclically loading threaded fasteners under impact fatigue. Specimen of steel-aluminum threaded connection is specifically designed for focusing on mere aluminum thread failure. Impact fatigue of 1 kHz around are successfully conducted, enabling to precisely determine mechanical behaviors of each cyclic and impact fatigue life under varying tensile loads. It is demonstrated that, its impact fatigue life is strongly dependent on loading stress amplitude. More importantly, irreversible damage occurring in threads, presents in the overall linear-elastic phase of the connection under impact fatigue loading, leading to progressive degradation of mechanical properties and eventual failure. Failure mode is predicted experimentally and verified by finite element simulated results, of uneven load/stress distribution across threads where higher stress concentrations occur near thread root, making them more susceptible to failure and progressive degradation.

{"title":"Failure behaviours of steel/aluminium threaded connections under impact fatigue","authors":"Chenxu Zhang , Ruoheng Sun , Jianping Yin , Yilun Hu , Qingbo Dou , Zhongbin Tang , Yinggang Miao , Yulong Li","doi":"10.1016/j.engfailanal.2025.109473","DOIUrl":"10.1016/j.engfailanal.2025.109473","url":null,"abstract":"<div><div>Threaded connections work as essential components in engineering structures, covering multiple industries such as aerospace and construction. However, they are frequently exposed to complex loadings of dynamic and impact loads, which even result in unexpected fatigue failure. In this study, we modify Hopkinson tension bar technique by guiding stress wave reflection, to achieve controllable cyclically loading threaded fasteners under impact fatigue. Specimen of steel-aluminum threaded connection is specifically designed for focusing on mere aluminum thread failure. Impact fatigue of 1 kHz around are successfully conducted, enabling to precisely determine mechanical behaviors of each cyclic and impact fatigue life under varying tensile loads. It is demonstrated that, its impact fatigue life is strongly dependent on loading stress amplitude. More importantly, irreversible damage occurring in threads, presents in the overall linear-elastic phase of the connection under impact fatigue loading, leading to progressive degradation of mechanical properties and eventual failure. Failure mode is predicted experimentally and verified by finite element simulated results, of uneven load/stress distribution across threads where higher stress concentrations occur near thread root, making them more susceptible to failure and progressive degradation.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109473"},"PeriodicalIF":4.4,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552221","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

The elastoplastic semi-analytic solution of a timely active support technique using NPR bolts for deeply-buried tunnels

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-03 DOI: 10.1016/j.engfailanal.2025.109477

Hongru Li , Manchao He , Yingming Xiao , Shulin Ren , Congling Shi

The timely active support technique using high-strength, high-toughness negative Poisson’s ratio (NPR) bolts as the key material (NPR-TAST) has a positive effect on disaster control in deeply buried tunnels. In this study, based on the finite difference method, a semi-analytical solution for NPR-TAST is proposed to investigate the effect of NPR bolts on ground reactions. The stress relief coefficient method is adopted to simulate the unloading process and the interaction process between the bolts and surrounding rock. Once the bolt deformation exceeds the set maximum value, the bolt would break. The proposed solution is validated by the previous semi-analytical and numerical solutions. The results show that, under large deformation conditions, conventional bolts tend to break. In contrast, NPR bolts can continuously deform with the surrounding rock, enhancing the bearing capacity of the surrounding rock. The key factors of NPR-TAST, including support timing, pre-stress magnitude, and constant resistance value of NPR bolts, are discussed. Early application of higher pre-stressed NPR bolts and increasing the constant resistance value of these bolts can more effectively control surrounding rock deformation and failure. The research results can provide guidance for the application of NPR-TAST in deeply buried tunnels.

{"title":"The elastoplastic semi-analytic solution of a timely active support technique using NPR bolts for deeply-buried tunnels","authors":"Hongru Li , Manchao He , Yingming Xiao , Shulin Ren , Congling Shi","doi":"10.1016/j.engfailanal.2025.109477","DOIUrl":"10.1016/j.engfailanal.2025.109477","url":null,"abstract":"<div><div>The timely active support technique using high-strength, high-toughness negative Poisson’s ratio (NPR) bolts as the key material (NPR-TAST) has a positive effect on disaster control in deeply buried tunnels. In this study, based on the finite difference method, a semi-analytical solution for NPR-TAST is proposed to investigate the effect of NPR bolts on ground reactions. The stress relief coefficient method is adopted to simulate the unloading process and the interaction process between the bolts and surrounding rock. Once the bolt deformation exceeds the set maximum value, the bolt would break. The proposed solution is validated by the previous semi-analytical and numerical solutions. The results show that, under large deformation conditions, conventional bolts tend to break. In contrast, NPR bolts can continuously deform with the surrounding rock, enhancing the bearing capacity of the surrounding rock. The key factors of NPR-TAST, including support timing, pre-stress magnitude, and constant resistance value of NPR bolts, are discussed. Early application of higher pre-stressed NPR bolts and increasing the constant resistance value of these bolts can more effectively control surrounding rock deformation and failure. The research results can provide guidance for the application of NPR-TAST in deeply buried tunnels.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109477"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561747","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Experimental study of diesel engine deposits on failure of honed cylinder liner surface texture

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-03 DOI: 10.1016/j.engfailanal.2025.109476

Daigeng Wu , Xingyu Liang , Xue Wen , Zhongwei Meng , Zehui Yu , Yongdi He , Peng Dai , Yonglin Yu , Nan Li

Studying the wear of cylinder liner and piston ring caused by deposits helps improve engine reliability. Deposits generated from a coastal diesel engine are collected, including impurity deposits from intake duct (#1) and carbon deposits from piston (#2), piston ring (#3), and cylinder liner top (#4). Using reciprocating friction tester, the influence of #1 and #2 on surface wear is studied under varying oil film thicknesses. Then combining Inductively Coupled Plasma Mass Spectrometer (ICP-MS), Thermogravimetric Analysis (TGA), and Scanning Electron Microscope (SEM) to explore potential wear mechanism. Results show that insufficient lubrication and the presence of intake duct deposits are the two main causes of wear. Under low oil film thickness (Oil-L), a transition from good to poor lubrication occurs, leading to increased wear. Adding deposits significantly increases the coefficient of friction (COF). However, insufficient lubrication poses higher wear risks than the absence of lubrication. Among them, ‘#1 + Oil-L’ exhibits the most severe wear, with the COF rising from 0.530 (#1 only) to 0.619 and producing the deepest scratch of 32 μm. This severe wear after adding #1 correlates with a higher proportion of sand and metal shown in physicochemical analysis, as well as the needle-like Fe₂O₃ corrosion products observed after TGA oxidation. Additionally, this study also discusses the possible reasons for insufficient lubrication and the potential effect of detected lubricant contamination in this engine. Enhancing engine lubrication and controlling intake impurities are critical strategies to mitigate abnormal honing texture wear.

{"title":"Experimental study of diesel engine deposits on failure of honed cylinder liner surface texture","authors":"Daigeng Wu , Xingyu Liang , Xue Wen , Zhongwei Meng , Zehui Yu , Yongdi He , Peng Dai , Yonglin Yu , Nan Li","doi":"10.1016/j.engfailanal.2025.109476","DOIUrl":"10.1016/j.engfailanal.2025.109476","url":null,"abstract":"<div><div>Studying the wear of cylinder liner and piston ring caused by deposits helps improve engine reliability. Deposits generated from a coastal diesel engine are collected, including impurity deposits from intake duct (#1) and carbon deposits from piston (#2), piston ring (#3), and cylinder liner top (#4). Using reciprocating friction tester, the influence of #1 and #2 on surface wear is studied under varying oil film thicknesses. Then combining Inductively Coupled Plasma Mass Spectrometer (ICP-MS), Thermogravimetric Analysis (TGA), and Scanning Electron Microscope (SEM) to explore potential wear mechanism. Results show that insufficient lubrication and the presence of intake duct deposits are the two main causes of wear. Under low oil film thickness (Oil-L), a transition from good to poor lubrication occurs, leading to increased wear. Adding deposits significantly increases the coefficient of friction (COF). However, insufficient lubrication poses higher wear risks than the absence of lubrication. Among them, ‘#1 + Oil-L’ exhibits the most severe wear, with the COF rising from 0.530 (#1 only) to 0.619 and producing the deepest scratch of 32 μm. This severe wear after adding #1 correlates with a higher proportion of sand and metal shown in physicochemical analysis, as well as the needle-like Fe<sub>2</sub>O<sub>3</sub> corrosion products observed after TGA oxidation. Additionally, this study also discusses the possible reasons for insufficient lubrication and the potential effect of detected lubricant contamination in this engine. Enhancing engine lubrication and controlling intake impurities are critical strategies to mitigate abnormal honing texture wear.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109476"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561748","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

Effect of bio-mimicked surface texturing on the shear strength of additively manufactured metal single-lap joints: An innovative approach

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-03 DOI: 10.1016/j.engfailanal.2025.109460

M. Gokhan Atahan , Ian Maskery , Ian Ashcroft , M. Kemal Apalak , Athanasios Pappas

In this paper, we investigate the mechanical performance of metal single-lap joints featuring bio-mimicking surface textures. The inspiration for the surface textures was the foot and toe of the gecko, a creature whose ability to climb smooth shear surfaces is attributed to the meso- and micro-structures of its feet. Three surface textures were investigated: a hexagonal texture based on the central region of the foot, a lamellae-like texture based on the toe, and a mixed texture of both. Metal adherends with these textures were produced using the laser powder bed fusion (LPBF) additive manufacturing method. Finite element analysis was performed to examine the influence of surface texture on stress distribution in the adhesive layer, while mechanical testing was used to determine joint strength and failure mode. Compared to the as-printed surface texture, bio-mimicking surface textures improved the wettability of the bonding surfaces, and significantly improved the lap shear strength of the joints. Mechanical interlocking due to surface texture was more effective than the increase in bonding surface area in enhancing joint strength. The bio-mimicking textures improved the damage tolerance capacity of the joints by reducing local stress concentrations at the overlap edges of the adhesive layer and ensured that the adhesive failure type was mixed mode due to the mechanical interlocking effect. The presented novel bio-mimicked surface texture method offers promising results for both industrial applications and scientific studies.

{"title":"Effect of bio-mimicked surface texturing on the shear strength of additively manufactured metal single-lap joints: An innovative approach","authors":"M. Gokhan Atahan , Ian Maskery , Ian Ashcroft , M. Kemal Apalak , Athanasios Pappas","doi":"10.1016/j.engfailanal.2025.109460","DOIUrl":"10.1016/j.engfailanal.2025.109460","url":null,"abstract":"<div><div>In this paper, we investigate the mechanical performance of metal single-lap joints featuring bio-mimicking surface textures. The inspiration for the surface textures was the foot and toe of the gecko, a creature whose ability to climb smooth shear surfaces is attributed to the meso- and micro-structures of its feet. Three surface textures were investigated: a hexagonal texture based on the central region of the foot, a lamellae-like texture based on the toe, and a mixed texture of both. Metal adherends with these textures were produced using the laser powder bed fusion (LPBF) additive manufacturing method. Finite element analysis was performed to examine the influence of surface texture on stress distribution in the adhesive layer, while mechanical testing was used to determine joint strength and failure mode. Compared to the as-printed surface texture, bio-mimicking surface textures improved the wettability of the bonding surfaces, and significantly improved the lap shear strength of the joints. Mechanical interlocking due to surface texture was more effective than the increase in bonding surface area in enhancing joint strength. The bio-mimicking textures improved the damage tolerance capacity of the joints by reducing local stress concentrations at the overlap edges of the adhesive layer and ensured that the adhesive failure type was mixed mode due to the mechanical interlocking effect. The presented novel bio-mimicked surface texture method offers promising results for both industrial applications and scientific studies.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109460"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552219","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

A limited annotated sample fault diagnosis algorithm based on nonlinear coupling self-attention mechanism

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-03 DOI: 10.1016/j.engfailanal.2025.109474

Shuyang Luo , Dong Zhang , Jinhong Wu , Yanzhi Wang , Qi Zhou , Jiexiang Hu

Deep learning-based intelligent diagnostic algorithms are regarded as a technology with significant industrial application prospects. However, acquiring sufficient annotated samples for training remains challenging in practice application, rendering the model susceptible to overfitting. To tackle the issue, a semi-supervised learning algorithm based on nonlinear coupling self-attention mechanism (NCSAM) is proposed for fault diagnosis with scarce annotated samples. Specifically, the method combines a pre-training model using multi-scale convolutional autoencoder (MSCAE) with a novel pre-training approach based on signal transformation to extract generic features from an ample number of unlabeled samples. On this basis, a nonlinear coupling self-attention mechanism is designed to adaptively explore both linear and nonlinear information in input data, achieving the integration of multi-scale features. Finally, the fault classification is completed using a linear classifier. The effectiveness of the proposed method has been validated on two public datasets. The results demonstrate that even with extremely limited annotated samples, the method achieves an accuracy of 97.83%, a 4.74% improvement over the baseline. Additionally, extensive comparative experiments with both semi-supervised and supervised algorithms have been designed to confirm the advantages of the proposed approach. In contrast, the diagnostic performance of the proposed method surpasses that of other methods.

{"title":"A limited annotated sample fault diagnosis algorithm based on nonlinear coupling self-attention mechanism","authors":"Shuyang Luo , Dong Zhang , Jinhong Wu , Yanzhi Wang , Qi Zhou , Jiexiang Hu","doi":"10.1016/j.engfailanal.2025.109474","DOIUrl":"10.1016/j.engfailanal.2025.109474","url":null,"abstract":"<div><div>Deep learning-based intelligent diagnostic algorithms are regarded as a technology with significant industrial application prospects. However, acquiring sufficient annotated samples for training remains challenging in practice application, rendering the model susceptible to overfitting. To tackle the issue, a semi-supervised learning algorithm based on nonlinear coupling self-attention mechanism (NCSAM) is proposed for fault diagnosis with scarce annotated samples. Specifically, the method combines a pre-training model using multi-scale convolutional autoencoder (MSCAE) with a novel pre-training approach based on signal transformation to extract generic features from an ample number of unlabeled samples. On this basis, a nonlinear coupling self-attention mechanism is designed to adaptively explore both linear and nonlinear information in input data, achieving the integration of multi-scale features. Finally, the fault classification is completed using a linear classifier. The effectiveness of the proposed method has been validated on two public datasets. The results demonstrate that even with extremely limited annotated samples, the method achieves an accuracy of 97.83%, a 4.74% improvement over the baseline. Additionally, extensive comparative experiments with both semi-supervised and supervised algorithms have been designed to confirm the advantages of the proposed approach. In contrast, the diagnostic performance of the proposed method surpasses that of other methods.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109474"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552220","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Experimental and simulation study on the microstructural evolution and fatigue life of 316L stainless steel under different periodic overload conditions

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-03 DOI: 10.1016/j.engfailanal.2025.109475

Haifeng Zhai , Wei Jiang , Yang Wang , Yanzhao Yang , Haiting Lv

Accurate fatigue life prediction under periodic overload conditions is crucial for ensuring the reliability of engineering structures. This study investigates the low-cycle fatigue (LCF) behavior of 316L stainless steel under various overload conditions, considering key factors such as strain amplitude, consecutive overload cycles, load sequence, and cycle interval. The results indicate that their influence on fatigue life follows a descending order of significance. Notably, this study innovatively identifies that irregular overload intervals can induce an internal “training effect”, effectively delaying fatigue damage. Furthermore, an improved fatigue life prediction method tailored for overload conditions is proposed and validated through experimental results. These findings provide new insights into fatigue damage mechanisms under periodic overload conditions and offer valuable guidance for refining fatigue life prediction models and optimizing engineering design strategies.

引用次数: 0

Structural assessment and retrofitting of an old building in highly seismic zone of Pakistan

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-03 DOI: 10.1016/j.engfailanal.2025.109478

Obaidullah khan , Muhammad Faisal Javed , Sanaullah Khan

This study evaluates the seismic performance of a 40-year-old, four-story reinforced concrete building in Abbottabad, Pakistan, a highly seismic region. The structure, designed without adherence to current seismic provisions outlined in the Building Code of Pakistan 2021, was analyzed using a displacement-based approach (nonlinear static analysis) and incremental dynamic analysis (nonlinear dynamic analysis). The static analysis revealed that the building met performance objectives but exhibited low base shear and stiffness in its longer (x) direction, leading to significant member-level damage. Dynamic analysis further highlighted excessive drift and displacement in the x-direction, attributed to the building’s stiff-weak configuration, with excessive stiffness in the shorter (y) direction to support gravity loads and insufficient strength in the x-direction. To mitigate these vulnerabilities, shear walls were analytically introduced in the x-direction, effectively controlling displacement and reducing damage. The findings underscore the need for retrofitting older structures to enhance seismic resilience in high-risk regions.

{"title":"Structural assessment and retrofitting of an old building in highly seismic zone of Pakistan","authors":"Obaidullah khan , Muhammad Faisal Javed , Sanaullah Khan","doi":"10.1016/j.engfailanal.2025.109478","DOIUrl":"10.1016/j.engfailanal.2025.109478","url":null,"abstract":"<div><div>This study evaluates the seismic performance of a 40-year-old, four-story reinforced concrete building in Abbottabad, Pakistan, a highly seismic region. The structure, designed without adherence to current seismic provisions outlined in the Building Code of Pakistan 2021, was analyzed using a displacement-based approach (nonlinear static analysis) and incremental dynamic analysis (nonlinear dynamic analysis). The static analysis revealed that the building met performance objectives but exhibited low base shear and stiffness in its longer (x) direction, leading to significant member-level damage. Dynamic analysis further highlighted excessive drift and displacement in the x-direction, attributed to the building’s stiff-weak configuration, with excessive stiffness in the shorter (y) direction to support gravity loads and insufficient strength in the x-direction. To mitigate these vulnerabilities, shear walls were analytically introduced in the x-direction, effectively controlling displacement and reducing damage. The findings underscore the need for retrofitting older structures to enhance seismic resilience in high-risk regions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109478"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579351","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 and guidelines for further exploitation of centrifugal slurry pumps used for copper flotation waste transport: A case study

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-03 DOI: 10.1016/j.engfailanal.2025.109479

Jakub Wróbel , Damian Pietrusiak , Radosław Rozmus , Robert Roicki , Bartłomiej Zarzycki , Paweł Stefanek

High power slurry pumps are the core element of copper flotation waste transport. Pump failure can lead to shutdowns of the flotation process and high financial losses. This paper is a case study of three high power, split case, rubber lined, closed impeller, tangential discharge slurry pump failures, where all failed pumps were located at the first stage of three different pumping sections. Analysis of the material strength of each pump housing showed a strong reduction in the ultimate tensile strength to 25 %, 39 % and 46 % of the specified min value of 241 MPa for ASTM A48 Class 35 Gray Iron Castings. Microstructure analysis showed numerous micro cracks formed along with casting defects such as cementite, phosphorus eutectic and porosities. Vibration analysis identified interference between pump stages that led to low frequency beat phenomena that consequently could cause cyclic load on the castings. Detailed FEM modeling of the pump housing assembly, including main bolted connections, indicated that tightening the pump housing bolts with the correct torque or operation at a nominal pressure of 0.69 MPa could cause the pump housing to fail due to strongly reduced material properties. Further investigation showed that the ASTM A48 Class 35 Gray Iron and cast stainless steel bodies A743 CA6NM did not show overload both when the housings are properly bolted together and when a 30 % overload is introduced on one of the fasteners, given the proper material properties.

{"title":"Failure analysis and guidelines for further exploitation of centrifugal slurry pumps used for copper flotation waste transport: A case study","authors":"Jakub Wróbel , Damian Pietrusiak , Radosław Rozmus , Robert Roicki , Bartłomiej Zarzycki , Paweł Stefanek","doi":"10.1016/j.engfailanal.2025.109479","DOIUrl":"10.1016/j.engfailanal.2025.109479","url":null,"abstract":"<div><div>High power slurry pumps are the core element of copper flotation waste transport. Pump failure can lead to shutdowns of the flotation process and high financial losses. This paper is a case study of three high power, split case, rubber lined, closed impeller, tangential discharge slurry pump failures, where all failed pumps were located at the first stage of three different pumping sections. Analysis of the material strength of each pump housing showed a strong reduction in the ultimate tensile strength to 25 %, 39 % and 46 % of the specified min value of 241 MPa for ASTM A48 Class 35 Gray Iron Castings. Microstructure analysis showed numerous micro cracks formed along with casting defects such as cementite, phosphorus eutectic and porosities. Vibration analysis identified interference between pump stages that led to low frequency beat phenomena that consequently could cause cyclic load on the castings. Detailed FEM modeling of the pump housing assembly, including main bolted connections, indicated that tightening the pump housing bolts with the correct torque or operation at a nominal pressure of 0.69 MPa could cause the pump housing to fail due to strongly reduced material properties. Further investigation showed that the ASTM A48 Class 35 Gray Iron and cast stainless steel bodies A743 CA6NM did not show overload both when the housings are properly bolted together and when a 30 % overload is introduced on one of the fasteners, given the proper material properties.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109479"},"PeriodicalIF":4.4,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579343","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

Influence of concrete interfaces on the damage and pull-out behavior of 3D-printed concrete structures

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2025-03-02 DOI: 10.1016/j.engfailanal.2025.109470

Qamar Shahzad, Fangyuan Li

This research examines the pull-out behavior of steel reinforcement bars embedded within 3D-printed concrete (3DPC) specimens. A finite element model (FEM) incorporating cohesive elements was developed and validated through experimental data to assess the impact of printed concrete-to-concrete interfaces on the pull-out behavior of 3DPC. A detailed analysis of the interfaces’ influence on the 3D printed specimens revealed the peak load and slip behavior, failure mechanisms, and damage criteria. Additionally, a thorough investigation was conducted on how interfacial bond strength, layer and strip dimensions, print angle, and effective length of bond impact on pull-out behavior of 3DPC. The results reveal that 3DPC demonstrates reduced initial stiffness compared to cast specimens, maintaining consistent stiffness in both the X and Y directions. The mold-cast specimen demonstrates a 9.38 % higher load-bearing capacity than the interlayer 3D printed specimen and a 25 % higher load-bearing capacity than the interstrip 3D printed specimen. The percentage difference between the experimental and simulated results for these specimens is less than 5 %, indicating good agreement. The study shows that the peak load changes with the print angle, initially decreasing from 0° to 30° and then rising from 30° to 90°, with the maximum load occurring at 90°. Specimens printed at a 30° angle exhibit the highest damage due to increased stress concentrations, while those printed at 90° experience lowest damage because of more effective stress distribution. Additionally, increasing the layer size significantly enhances peak load capacity, with larger layers improving load distribution and structural support. Ultimately, specimens with a 50 mm bond length demonstrate the highest peak load and the lowest slip, indicating superior load-bearing capacity and bond performance. In contrast, shorter bond lengths result in lower peak loads and greater slip values. In conclusion, this study provides a foundation for future research on 3DPC modeling, particularly regarding concrete interfaces.

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