Pub Date : 2026-03-15Epub Date: 2025-12-29DOI: 10.1016/j.engfailanal.2025.110513
Yong Yue , Zitu Chen , Xin Jin , Junchi Chen , An Wu
To address the challenge of achieving rapid and accurate fatigue crack life prediction, this study proposes a novel methodology that integrates Finite Element Modeling (FEM) with a hybrid CNN-LSTM-KAN network augmented by a temporal self-attention mechanism, focusing on wind turbine gearbox teeth. The methodology begins with developing finite element and crack sub-models of helical gears using ABAQUS and FRANC3D to generate a high-fidelity dataset. This dataset is then utilized to train, validate, and test the proposed hybrid model. The temporal self-attention mechanism is rigorously benchmarked against two other attention architectures to demonstrate its superiority. Furthermore, the overall performance is evaluated against four traditional deep learning models across multiple metrics. On the test set, the proposed method achieves a MAPE of 3.81%, RMSE of 0.4754, and R2 of 0.99442. In the final prediction phase, a comparative analysis with established models (MLR, GRU, LSTM, BiLSTM, and CNN-LSTM) using simulation data reveals that the proposed method achieves the lowest average error of 0.689%, significantly outperforming others which range from 2.005% to 30.958%. These results conclusively demonstrate the method’s superior computational efficiency and high predictive accuracy, with errors consistently below 1% of simulation benchmarks.
{"title":"A novel framework integrating finite element analysis with deep learning for wind turbine gear crack propagation life prediction","authors":"Yong Yue , Zitu Chen , Xin Jin , Junchi Chen , An Wu","doi":"10.1016/j.engfailanal.2025.110513","DOIUrl":"10.1016/j.engfailanal.2025.110513","url":null,"abstract":"<div><div>To address the challenge of achieving rapid and accurate fatigue crack life prediction, this study proposes a novel methodology that integrates Finite Element Modeling (FEM) with a hybrid CNN-LSTM-KAN network augmented by a temporal self-attention mechanism, focusing on wind turbine gearbox teeth. The methodology begins with developing finite element and crack sub-models of helical gears using ABAQUS and FRANC3D to generate a high-fidelity dataset. This dataset is then utilized to train, validate, and test the proposed hybrid model. The temporal self-attention mechanism is rigorously benchmarked against two other attention architectures to demonstrate its superiority. Furthermore, the overall performance is evaluated against four traditional deep learning models across multiple metrics. On the test set, the proposed method achieves a MAPE of 3.81%, RMSE of 0.4754, and R<sup>2</sup> of 0.99442. In the final prediction phase, a comparative analysis with established models (MLR, GRU, LSTM, BiLSTM, and CNN-LSTM) using simulation data reveals that the proposed method achieves the lowest average error of 0.689%, significantly outperforming others which range from 2.005% to 30.958%. These results conclusively demonstrate the method’s superior computational efficiency and high predictive accuracy, with errors consistently below 1% of simulation benchmarks.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110513"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921423","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}
Pub Date : 2026-03-15Epub Date: 2025-12-31DOI: 10.1016/j.engfailanal.2025.110520
Jian Zhao, Qiang Wan, Chaoyang Xie
Widely used in complex equipment, prestressed multilayer cylindrical structures with the silicone foam cushion are prone to the interlayer relative rotation failure under vibration and aging conditions. Finite element (FE) simulations were performed to analyze influence factors (prestressed offset, vibration frequencies in X and Y axial directions, phase difference of vibrations, amplitude and aging degradation), involving modal analyses and relative rotation angle calculations under the vibration. Results show that the relative rotation is most significant at the 4th natural frequency of the structure, with the frequency ratio between X to Y directions 1 and 90° phase difference. Additionally, the rotation angle increases monotonically with vibration amplitude. Aging effect of the silicone foam cushion was characterized by shear modulus and simulations indicated that the natural frequencies increase as the aging time extends. For a constant prestressed offset, the maximum relative rotation angle decreases with increasing aging time. To identify the key features and improve the prediction accuracy, a random forest model was used to analyze the feature importance, and the Gaussian Process Regression model was trained and tested. The combination of FE simulation, feature importance analysis and machine learning model development in this work provide effective methods for the interlayer relative rotation failure evaluation of the prestressed multilayer cylinder in engineering.
{"title":"Relative rotation failure analysis of prestressed multilayer cylinder considering vibration and aging effect","authors":"Jian Zhao, Qiang Wan, Chaoyang Xie","doi":"10.1016/j.engfailanal.2025.110520","DOIUrl":"10.1016/j.engfailanal.2025.110520","url":null,"abstract":"<div><div>Widely used in complex equipment, prestressed multilayer cylindrical structures with the silicone foam cushion are prone to the interlayer relative rotation failure under vibration and aging conditions. Finite element (FE) simulations were performed to analyze influence factors (prestressed offset, vibration frequencies in X and Y axial directions, phase difference of vibrations, amplitude and aging degradation), involving modal analyses and relative rotation angle calculations under the vibration. Results show that the relative rotation is most significant at the 4th natural frequency of the structure, with the frequency ratio between X to Y directions 1 and 90° phase difference. Additionally, the rotation angle increases monotonically with vibration amplitude. Aging effect of the silicone foam cushion was characterized by shear modulus and simulations indicated that the natural frequencies increase as the aging time extends. For a constant prestressed offset, the maximum relative rotation angle decreases with increasing aging time. To identify the key features and improve the prediction accuracy, a random forest model was used to analyze the feature importance, and the Gaussian Process Regression model was trained and tested. The combination of FE simulation, feature importance analysis and machine learning model development in this work provide effective methods for the interlayer relative rotation failure evaluation of the prestressed multilayer cylinder in engineering.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110520"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921730","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}
Pub Date : 2026-03-15Epub Date: 2026-01-08DOI: 10.1016/j.engfailanal.2026.110558
Rajai Z. Al-Rousan, Bara’a R. Alnemrawi
This study highlights the effect of strengthening heat-damaged reinforced concrete (RC) slabs with carbon fiber reinforced polymers (CFRP) sheets, which were anchored at their ends to enhance their performance and prevent brittle debonding failure. The efficiency of the anchoring system was examined using a total of twenty-four specimens tested under the effect of different slab depths (60, 80, and 100) mm, temperatures (23, 200, 400, and 600) C, and the CFRF anchoring system (anchored and unanchored). Results show that the structural behavior is significantly improved upon the anchoring, including all its characteristics, and the enhancement extent is directly related to the higher benefit from the CFRP high tensile strength, where the final failure was delayed without premature early debonding or delamination. However, the failure mode, cracking patterns, and the resulting improvement by the CFRP strengthening efficiency mainly depend on the damage level. Increasing the exposure temperature for heat-damaged specimens resulted in increasing the crack-bridging ability provided by the CFRP strengthening material. Finally, results revealed that the efficiency of the anchored CFRP composites increased by 13% to 33% which ends up with improving the strength, ductility, and durability of the heat-damaged RC slabs.
{"title":"The optimum upgrade in the flexural capacity of heat-damaged one-way RC slabs strengthened with anchored CFRP sheets","authors":"Rajai Z. Al-Rousan, Bara’a R. Alnemrawi","doi":"10.1016/j.engfailanal.2026.110558","DOIUrl":"10.1016/j.engfailanal.2026.110558","url":null,"abstract":"<div><div>This study highlights the effect of strengthening heat-damaged reinforced concrete (RC) slabs with carbon fiber reinforced polymers (CFRP) sheets, which were anchored at their ends to enhance their performance and prevent brittle debonding failure. The efficiency of the anchoring system was examined using a total of twenty-four specimens tested under the effect of different slab depths (60, 80, and 100) mm, temperatures (23, 200, 400, and 600)<span><math><mrow><msup><mrow><mspace></mspace></mrow><mo>°</mo></msup></mrow></math></span> C, and the CFRF anchoring system (anchored and unanchored). Results show that the structural behavior is significantly improved upon the anchoring, including all its characteristics, and the enhancement extent is directly related to the higher benefit from the CFRP high tensile strength, where the final failure was delayed without premature early debonding or delamination. However, the failure mode, cracking patterns, and the resulting improvement by the CFRP strengthening efficiency mainly depend on the damage level. Increasing the exposure temperature for heat-damaged specimens resulted in increasing the crack-bridging ability provided by the CFRP strengthening material. Finally, results revealed that the efficiency of the anchored CFRP composites increased by 13% to 33% which ends up with improving the strength, ductility, and durability of the heat-damaged RC slabs.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110558"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921731","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}
Pub Date : 2026-03-15Epub Date: 2025-12-19DOI: 10.1016/j.engfailanal.2025.110472
Carlos Avilés-Cruz , Miriam Aguilar-Sánchez , Benjamin Vargas-Arista , Celso Eduardo Cruz-González , Elizabeth Garfias-García , Gabriel Celis-Escudero
This study presents a novel, Deep Learning-based methodology for predicting the stress–strain curves of high strength low alloy (HSLA) steel welded joints, based directly on fractographic images obtained via scanning electron microscopy, as the primary input. Robotic pulsed gas tungsten arc welding (P-GTAW) was used to produce HSLA steel specimens displaying both ductile and brittle fracture mechanisms. Each specimen was subjected to tensile testing and the resulting fracture surfaces were examined using conventional fractographic analysis. The resulting SEM images were then used to train a deep learning model to recognize fracture morphologies automatically. A convolutional neural network was trained to perform two tasks: (i) classification of fracture type and (II) generation of corresponding stress–strain curves. The predicted curves closely matched the experimental results, thus establishing a pathway for the first time that links fracture morphology to the full stress–strain behavior of tensile testing in welded joints.
{"title":"Predicting stress–strain curves using a new deep learning model based on fractography","authors":"Carlos Avilés-Cruz , Miriam Aguilar-Sánchez , Benjamin Vargas-Arista , Celso Eduardo Cruz-González , Elizabeth Garfias-García , Gabriel Celis-Escudero","doi":"10.1016/j.engfailanal.2025.110472","DOIUrl":"10.1016/j.engfailanal.2025.110472","url":null,"abstract":"<div><div>This study presents a novel, Deep Learning-based methodology for predicting the stress–strain curves of high strength low alloy (HSLA) steel welded joints, based directly on fractographic images obtained via scanning electron microscopy, as the primary input. Robotic pulsed gas tungsten arc welding (P-GTAW) was used to produce HSLA steel specimens displaying both ductile and brittle fracture mechanisms. Each specimen was subjected to tensile testing and the resulting fracture surfaces were examined using conventional fractographic analysis. The resulting SEM images were then used to train a deep learning model to recognize fracture morphologies automatically. A convolutional neural network was trained to perform two tasks: (i) classification of fracture type and (II) generation of corresponding stress–strain curves. The predicted curves closely matched the experimental results, thus establishing a pathway for the first time that links fracture morphology to the full stress–strain behavior of tensile testing in welded joints.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110472"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788646","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}
Pub Date : 2026-03-15Epub Date: 2025-12-17DOI: 10.1016/j.engfailanal.2025.110477
Chenkun Xu , Zhi Wang , Le Zhou , Feng Wang , Ziqi Wei , Pingli Mao
This paper systematically investigates the effects of Ce addition on the dynamic mechanical behavior and fracture failure mechanisms of ZK60 alloy. The results indicate that the introduction of Ce leads to the formation of thermally stable Mg-Zn-Ce ternary phases, effectively refining the grain structure of the alloy and inhibiting grain growth during processing. Compared to the ZK60 alloy, the ZEK610 alloy exhibits superior overall dynamic mechanical properties, fracturing only at higher strain rates. Additionally, the fracture mode shifts from the typical fracture observed in the base alloy to a mixed mode dominated by brittle fracture with localized dimple-like ductile fracture. From the perspective of deformation mechanisms, the ZK60 alloy exhibits more active twin-twin interactions, while the ZEK610 alloy possesses a higher dislocation density and even generates < c + a > dislocations at an earlier stage. These differences directly account for the distinct dynamic deformation behaviors of the two alloys. From an energy perspective, the ΔE and the ΔT values of the ZEK610 alloy are significantly higher than those of the ZK60 alloy. This not only provides the energy conditions for the activation of non-basal slip but also leads to the transformation in the fracture mode of the ZEK610 alloy, serving as the fundamental reason for the differences in dynamic mechanical behavior and fracture failure mechanisms between the two alloys. Through microstructural refinement and stabilization, Ce alloying effectively enhances the dynamic mechanical properties and fracture toughness of the ZK60 alloy, offering a viable strategy for developing high-performance magnesium alloys with improved impact resistance.
本文系统地研究了添加Ce对ZK60合金动态力学行为的影响及断裂失效机理。结果表明，Ce的引入导致Mg-Zn-Ce三元相的形成，有效地细化了合金的晶粒组织，抑制了合金在加工过程中的晶粒长大。与ZK60合金相比，ZEK610合金具有更优越的整体动态力学性能，仅在更高的应变速率下发生断裂。断裂模式由基体的典型断裂转变为以脆性断裂为主、局部韧窝状韧性断裂为主的混合断裂模式。从变形机制来看，ZK60合金表现出更活跃的孪晶相互作用，而ZEK610合金具有更高的位错密度，甚至更早地产生<； c + a >；位错。这些差异直接解释了两种合金不同的动态变形行为。从能量角度看，ZEK610合金的ΔE和ΔT值明显高于ZK60合金。这不仅为非基滑移的激活提供了能量条件，而且导致了ZEK610合金断裂模式的转变，是两种合金动态力学行为和断裂破坏机制差异的根本原因。通过组织细化和稳定，Ce合金化有效地提高了ZK60合金的动态力学性能和断裂韧性，为开发抗冲击高性能镁合金提供了可行的策略。
{"title":"The influence of Ce element on the dynamic mechanical behavior and fracture failure behavior of ZK60 alloy","authors":"Chenkun Xu , Zhi Wang , Le Zhou , Feng Wang , Ziqi Wei , Pingli Mao","doi":"10.1016/j.engfailanal.2025.110477","DOIUrl":"10.1016/j.engfailanal.2025.110477","url":null,"abstract":"<div><div>This paper systematically investigates the effects of Ce addition on the dynamic mechanical behavior and fracture failure mechanisms of ZK60 alloy. The results indicate that the introduction of Ce leads to the formation of thermally stable Mg-Zn-Ce ternary phases, effectively refining the grain structure of the alloy and inhibiting grain growth during processing. Compared to the ZK60 alloy, the ZEK610 alloy exhibits superior overall dynamic mechanical properties, fracturing only at higher strain rates. Additionally, the fracture mode shifts from the typical fracture observed in the base alloy to a mixed mode dominated by brittle fracture with localized dimple-like ductile fracture. From the perspective of deformation mechanisms, the ZK60 alloy exhibits more active twin-twin interactions, while the ZEK610 alloy possesses a higher dislocation density and even generates < c + a > dislocations at an earlier stage. These differences directly account for the distinct dynamic deformation behaviors of the two alloys. From an energy perspective, the Δ<em>E</em> and the Δ<em>T</em> values of the ZEK610 alloy are significantly higher than those of the ZK60 alloy. This not only provides the energy conditions for the activation of non-basal slip but also leads to the transformation in the fracture mode of the ZEK610 alloy, serving as the fundamental reason for the differences in dynamic mechanical behavior and fracture failure mechanisms between the two alloys. Through microstructural refinement and stabilization, Ce alloying effectively enhances the dynamic mechanical properties and fracture toughness of the ZK60 alloy, offering a viable strategy for developing high-performance magnesium alloys with improved impact resistance.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110477"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788647","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}
Pub Date : 2026-03-15Epub Date: 2025-12-12DOI: 10.1016/j.engfailanal.2025.110461
Yue Chang , Zhimin Pan , Hong Luo , Qiancheng Zhao , Minglei Sun , Milos B. Djukic , Jun Cheng
This study investigates hydrogen-induced microstructure evolution and cracking in a novel Ni0.65Cr0.3Al0.05 alloy. The as-annealed state showed an f.c.c. structure (∼38.20 μm), while the as-aged state displayed f.c.c. + B2 + L12 phases with larger grains (∼84.78 μm). The as-annealed sample showed slight reductions in yield strength (248.03 ± 6.2 to 243.50 ± 8.3 MPa) and tensile strength (650.48 ± 7.5 to 637.95 ± 6.5 MPa) after hydrogen charging. In the as-aged state, the yield and tensile strengths changed from 310.08 ± 4.5 to 306.34 ± 6.9 MPa and 650.96 ± 7.6 to 640.60 ± 9.8 MPa. Elongation remained essentially unchanged in the as-annealed sample (52.20 ± 0.8 % to 52.24 ± 0.6 %), whereas the as-aged sample experienced a decrease from 79.50 ± 0.9 % to 70.90 ± 0.6 % (∼10.8 ± 1.3 % loss). These results indicate minimal hydrogen-embrittlement sensitivity in the as-annealed state under extreme charging conditions. Hydrogen embrittlement predominantly occurred via grain boundary (GB)- and twin boundary (TB)-assisted cracking, where the impingement of slip bands and microbands (MBs) at GBs and TBs led to high local hydrogen concentrations and stress concentrations, promoting micro-void formation and crack initiation through micro-void coalescence. High Cr content was expected to promote short-range order structures and lower stacking fault energy, which facilitated the formation of deformation twins (DTs) and MBs. This also subdivided grains and impeded the motion of hydrogen-carrying dislocations. This mechanism reduced local hydrogen segregation at GBs and TBs and dispersed hydrogen, thereby mitigating hydrogen embrittlement in the as-annealed sample.
{"title":"Defeating hydrogen induced embrittlement via introducing deformation twins and microbands in nickel-based alloys","authors":"Yue Chang , Zhimin Pan , Hong Luo , Qiancheng Zhao , Minglei Sun , Milos B. Djukic , Jun Cheng","doi":"10.1016/j.engfailanal.2025.110461","DOIUrl":"10.1016/j.engfailanal.2025.110461","url":null,"abstract":"<div><div>This study investigates hydrogen-induced microstructure evolution and cracking in a novel Ni<sub>0.65</sub>Cr<sub>0.3</sub>Al<sub>0.05</sub> alloy. The as-annealed state showed an f.c.c. structure (∼38.20 μm), while the as-aged state displayed f.c.c. + B2 + L1<sub>2</sub> phases with larger grains (∼84.78 μm). The as-annealed sample showed slight reductions in yield strength (248.03 ± 6.2 to 243.50 ± 8.3 MPa) and tensile strength (650.48 ± 7.5 to 637.95 ± 6.5 MPa) after hydrogen charging. In the as-aged state, the yield and tensile strengths changed from 310.08 ± 4.5 to 306.34 ± 6.9 MPa and 650.96 ± 7.6 to 640.60 ± 9.8 MPa. Elongation remained essentially unchanged in the as-annealed sample (52.20 ± 0.8 % to 52.24 ± 0.6 %), whereas the as-aged sample experienced a decrease from 79.50 ± 0.9 % to 70.90 ± 0.6 % (∼10.8 ± 1.3 % loss). These results indicate minimal hydrogen-embrittlement sensitivity in the as-annealed state under extreme charging conditions. Hydrogen embrittlement predominantly occurred via grain boundary (GB)- and twin boundary (TB)-assisted cracking, where the impingement of slip bands and microbands (MBs) at GBs and TBs led to high local hydrogen concentrations and stress concentrations, promoting micro-void formation and crack initiation through micro-void coalescence. High Cr content was expected to promote short-range order structures and lower stacking fault energy, which facilitated the formation of deformation twins (DTs) and MBs. This also subdivided grains and impeded the motion of hydrogen-carrying dislocations. This mechanism reduced local hydrogen segregation at GBs and TBs and dispersed hydrogen, thereby mitigating hydrogen embrittlement in the as-annealed sample.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110461"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788775","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}
Pub Date : 2026-03-15Epub Date: 2026-01-08DOI: 10.1016/j.engfailanal.2026.110562
Jinye Wang , Yu Feng , Kai Wu , Shaolei Wu , Wei Wang
Electrical connectors are electrical devices used for branching and connecting conductors in power distribution lines. Under wind loads, they undergo sustained vortex-induced periodic vibrations along with the conductors, causing fatigue and wear at the electrical contact interface and thereby reducing the reliability of electrical connections. This study selected cylindrical electrical connectors as the research subject. A constant-stress accelerated degradation test protocol was designed, employing vibration velocity as the accelerated stress and contact resistance as the performance degradation indicator. By analyzing the contact resistance variation curve and contact interface damage assessment, the failure mechanism of electrical connectors under vibrational environments was revealed, fully accounting for time-varying differences between the specimen and the degradation process. A nonlinear accelerated degradation model incorporating random effects was established, with model parameters solved using an iterative maximum likelihood estimation method. Based on this model, failure probability density curves and reliability curves for electrical connectors were plotted. By evaluating curve variations and extrema, the reliability of electrical connectors was assessed and their service life predicted, providing a robust theoretical foundation for maintenance strategies in power distribution networks.
{"title":"Accelerated failure characterization and reliability analysis of cylindrical electrical connectors under wind vibration environments","authors":"Jinye Wang , Yu Feng , Kai Wu , Shaolei Wu , Wei Wang","doi":"10.1016/j.engfailanal.2026.110562","DOIUrl":"10.1016/j.engfailanal.2026.110562","url":null,"abstract":"<div><div>Electrical connectors are electrical devices used for branching and connecting conductors in power distribution lines. Under wind loads, they undergo sustained vortex-induced periodic vibrations along with the conductors, causing fatigue and wear at the electrical contact interface and thereby reducing the reliability of electrical connections. This study selected cylindrical electrical connectors as the research subject. A constant-stress accelerated degradation test protocol was designed, employing vibration velocity as the accelerated stress and contact resistance as the performance degradation indicator. By analyzing the contact resistance variation curve and contact interface damage assessment, the failure mechanism of electrical connectors under vibrational environments was revealed, fully accounting for time-varying differences between the specimen and the degradation process. A nonlinear accelerated degradation model incorporating random effects was established, with model parameters solved using an iterative maximum likelihood estimation method. Based on this model, failure probability density curves and reliability curves for electrical connectors were plotted. By evaluating curve variations and extrema, the reliability of electrical connectors was assessed and their service life predicted, providing a robust theoretical foundation for maintenance strategies in power distribution networks.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110562"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973370","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}
Pub Date : 2026-03-15Epub Date: 2025-12-30DOI: 10.1016/j.engfailanal.2025.110515
Liyang Zhu , Zehua Dong , Guangyi Cai , Yizhou Li , Zhongyu Cui
To date, few studies have investigated the stress corrosion cracking (SCC) behavior of stainless steel under the combined influence of cold deformation and crevice, and the underlying mechanisms remain poorly understood. This study systematically examines the damage behavior of 304 stainless steel under the coupled effects of environment, cold deformation, stress, and crevice geometry using electrochemical measurements, surface analysis, and slow strain rate tensile (SSRT) testing. The results reveal that cold deformation introduces a high density of dislocations and induces martensitic transformation, with martensite content reaching approximately 31% and 44% at 15% and 30% deformation, respectively. This microstructural evolution degrades the protective quality of the passive film. Consequently, crevice corrosion is markedly accelerated, exhibiting increasing severity with greater deformation. The intensified localized corrosion acts as a stress concentrator, facilitating crack initiation. Subsequent crack propagation proceeds via a synergistic mechanism combining self-catalyzed dissolution at the crack tip and hydrogen embrittlement.
{"title":"The effect of cold deformation on crevice corrosion and stress corrosion cracking behavior of 304 stainless steel","authors":"Liyang Zhu , Zehua Dong , Guangyi Cai , Yizhou Li , Zhongyu Cui","doi":"10.1016/j.engfailanal.2025.110515","DOIUrl":"10.1016/j.engfailanal.2025.110515","url":null,"abstract":"<div><div>To date, few studies have investigated the stress corrosion cracking (SCC) behavior of stainless steel under the combined influence of cold deformation and crevice, and the underlying mechanisms remain poorly understood. This study systematically examines the damage behavior of 304 stainless steel under the coupled effects of environment, cold deformation, stress, and crevice geometry using electrochemical measurements, surface analysis, and slow strain rate tensile (SSRT) testing. The results reveal that cold deformation introduces a high density of dislocations and induces martensitic transformation, with martensite content reaching approximately 31% and 44% at 15% and 30% deformation, respectively. This microstructural evolution degrades the protective quality of the passive film. Consequently, crevice corrosion is markedly accelerated, exhibiting increasing severity with greater deformation. The intensified localized corrosion acts as a stress concentrator, facilitating crack initiation. Subsequent crack propagation proceeds via a synergistic mechanism combining self-catalyzed dissolution at the crack tip and hydrogen embrittlement.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110515"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880877","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}
Pub Date : 2026-03-15Epub Date: 2025-12-13DOI: 10.1016/j.engfailanal.2025.110456
Zifan Hu , Zhiqiang Zhang , Cheng Li , Chuanwen Sun , Xiaobo Cao , Yuzhe Jin , Asif Mahmood , Wei Li
Additive manufacturing of nanoparticle-reinforced metal matrix composites has emerged as a key load-bearing structural material for hot-section components in aerospace engines. However, the mechanisms involving high-temperature performance, reinforcement content, microstructural evolution, and fatigue behavior remain insufficiently understood. In this study, low content TiC/Ti6Al4V composite fabricated by laser powder bed fusion (LPBF) is investigated to clarify the mechanical response and multi-scale failure mechanisms at a service temperature of 450 °C. Experimental characterization, including SEM, EBSD, high-cycle fatigue testing, and TEM, reveals that under monotonic tension, the fracture surface is mainly ductile fracture, alongside localized brittle fracture from interface debonding, while fatigue cracks primarily initiate from internal defects, with stress-dependent fracture modes. Quantitative analysis demonstrates that the composite is strengthened by multiple mechanisms, with dislocation strengthening being dominant (63.5 %). Complementary molecular dynamics (MD) simulations validate these deformation mechanisms at the atomic scale and extend the analysis beyond the single experimentally tested composition. Predictions from an idealized MD model, which was mechanistically validated against a single experimental composition, suggest that a moderate TiC content (C1-C5 range) may offer a promising route to achieving an optimal balance of strength and toughness. However, this theoretical prediction urgently requires systematic experimental validation. These findings provide engineering guidelines for process optimization to mitigate premature failure and enhance service reliability in aerospace and energy applications.
{"title":"Multi-scale fatigue failure analysis and deformation-cracking-strengthening mechanisms of LPBF TiC/Ti6Al4V composites at service temperature","authors":"Zifan Hu , Zhiqiang Zhang , Cheng Li , Chuanwen Sun , Xiaobo Cao , Yuzhe Jin , Asif Mahmood , Wei Li","doi":"10.1016/j.engfailanal.2025.110456","DOIUrl":"10.1016/j.engfailanal.2025.110456","url":null,"abstract":"<div><div>Additive manufacturing of nanoparticle-reinforced metal matrix composites has emerged as a key load-bearing structural material for hot-section components in aerospace engines. However, the mechanisms involving high-temperature performance, reinforcement content, microstructural evolution, and fatigue behavior remain insufficiently understood. In this study, low content TiC/Ti6Al4V composite fabricated by laser powder bed fusion (LPBF) is investigated to clarify the mechanical response and multi-scale failure mechanisms at a service temperature of 450 °C. Experimental characterization, including SEM, EBSD, high-cycle fatigue testing, and TEM, reveals that under monotonic tension, the fracture surface is mainly ductile fracture, alongside localized brittle fracture from interface debonding, while fatigue cracks primarily initiate from internal defects, with stress-dependent fracture modes. Quantitative analysis demonstrates that the composite is strengthened by multiple mechanisms, with dislocation strengthening being dominant (63.5 %). Complementary molecular dynamics (MD) simulations validate these deformation mechanisms at the atomic scale and extend the analysis beyond the single experimentally tested composition. Predictions from an idealized MD model, which was mechanistically validated against a single experimental composition, suggest that a moderate TiC content (C1-C5 range) may offer a promising route to achieving an optimal balance of strength and toughness. However, this theoretical prediction urgently requires systematic experimental validation. These findings provide engineering guidelines for process optimization to mitigate premature failure and enhance service reliability in aerospace and energy applications.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110456"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788707","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}
Pub Date : 2026-03-15Epub Date: 2025-12-15DOI: 10.1016/j.engfailanal.2025.110465
Chenyi Liu, Bingwen Wang, Mingchao Kang, Yaning Fan, Zhao Wei, Lei Yang, Qianlong Li
Variations in the mining-induced stress field can readily trigger asymmetric deformation and failure in the surrounding rock of roadways, significantly compromising their stability and functional integrity. To address this issue, this study establishes a planar mechanical model of non-closed fractures under the influence of mining-induced stress fields. The analytical solution for the elastoplastic boundary at fracture tips under principal stress rotation is derived, and the influence of burial depth and mining-induced stress on the morphology and area of the fracture Tip Plastic Core Zone (TPCZ) is systematically examined. The results demonstrate that the TPCZ area gradually increases with greater burial depth. In stress environments characterized by lower lateral pressure coefficients, the TPCZ area shows heightened sensitivity to changes in fracture angle. An increase in the angle between the principal stress direction and the fractures promotes TPCZ expansion, whereas a decrease inhibits it. The uniaxial compressive strength of specimens containing combined fractures decreases markedly with an increase in the inclination angle of Fracture 1. Compared to the specimen with Fracture 1 at 0°, strength reductions of 7.9%, 19.3%, 30.1%, and 39.6% are observed when the angle is increased to 30°, 45°, 60°, and 90°, respectively. A TPCZ connectivity-induced crack propagation mechanism is proposed: cracks initiate and propagate preferentially within the TPCZ, and principal stress rotation facilitates the interconnection of TPCZs among multiple fractures, thereby guiding crack coalescence and the formation of macroscopic failure surfaces. Coupled FDM-DEM numerical simulations confirm the spatial evolution patterns of fractures and crack propagation under principal stress rotation, revealing the intrinsic mechanism underlying asymmetric roadway deformation. This study offers a novel perspective and theoretical foundation for the stability analysis and control of asymmetrically deformed roadways.
{"title":"Research on asymmetric deformation of roadway roof based on non-closed fracture propagation mechanism induced by principal stress rotation","authors":"Chenyi Liu, Bingwen Wang, Mingchao Kang, Yaning Fan, Zhao Wei, Lei Yang, Qianlong Li","doi":"10.1016/j.engfailanal.2025.110465","DOIUrl":"10.1016/j.engfailanal.2025.110465","url":null,"abstract":"<div><div>Variations in the mining-induced stress field can readily trigger asymmetric deformation and failure in the surrounding rock of roadways, significantly compromising their stability and functional integrity. To address this issue, this study establishes a planar mechanical model of non-closed fractures under the influence of mining-induced stress fields. The analytical solution for the elastoplastic boundary at fracture tips under principal stress rotation is derived, and the influence of burial depth and mining-induced stress on the morphology and area of the fracture Tip Plastic Core Zone (TPCZ) is systematically examined. The results demonstrate that the TPCZ area gradually increases with greater burial depth. In stress environments characterized by lower lateral pressure coefficients, the TPCZ area shows heightened sensitivity to changes in fracture angle. An increase in the angle between the principal stress direction and the fractures promotes TPCZ expansion, whereas a decrease inhibits it. The uniaxial compressive strength of specimens containing combined fractures decreases markedly with an increase in the inclination angle of Fracture 1. Compared to the specimen with Fracture 1 at 0°, strength reductions of 7.9%, 19.3%, 30.1%, and 39.6% are observed when the angle is increased to 30°, 45°, 60°, and 90°, respectively. A TPCZ connectivity-induced crack propagation mechanism is proposed: cracks initiate and propagate preferentially within the TPCZ, and principal stress rotation facilitates the interconnection of TPCZs among multiple fractures, thereby guiding crack coalescence and the formation of macroscopic failure surfaces. Coupled FDM-DEM numerical simulations confirm the spatial evolution patterns of fractures and crack propagation under principal stress rotation, revealing the intrinsic mechanism underlying asymmetric roadway deformation. This study offers a novel perspective and theoretical foundation for the stability analysis and control of asymmetrically deformed roadways.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110465"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788768","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}
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