Engineering Failure Analysis最新文献_第6页

Study on multi-scale mechanism and unclogging technology of granular particles adhesion hang-up in high ore pass 高溜井颗粒黏附悬吊多尺度机理及疏通技术研究

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-07 DOI: 10.1016/j.engfailanal.2026.110556

Yu Xiong , Lichun Jiang , Fei Li , Zhanglong Liu , Zhi Yang

To address the problem of granular particles adhesion hang-up in high ore passes, this study combines field investigation, particle size statistics, and the characterization of inter-particle adhesive mechanics. Through a multi-scale analysis that couples micro-agglomeration mechanism and macro-blocking conditions, it reveals the fundamental mechanical essence of ore pass hang-up. Furthermore, the efficient unclogging technology is put forward, and the engineering application is completed. The results show that the mechanical behavior of contact and adhesion of granular particles is significantly controlled by particle gradation, and the normal contact force F_n, tangential contact force F_s and capillary bridge force F_c all increase with the increase of particle size, among which the sharp increase of F_n, F_s and F_c under similar particle size combinations is the core inducement of hang-up. The contact angle ϕ and particle grading serve as coordinated control parameters for adhesive balance. Vertical (ϕ = 90°) and horizontal (ϕ = 0°) contact lead to the failure of normal and tangential adhesive due to the disparity of particle weight and particle size, respectively. Fine particles are prone to persistent hang-up due to agglomeration, rendering adjustments to ore pass diameter D, inclination α and granular height H in a specific range largely ineffective. Coarse particles can maintain the non-blocking state by eliminating the stress arch and increasing the advantages of load and gravity flow, that is, increasing α, D and H can reduce the risk of ore pass hang-up. Through blasting technology, the agglomeration and stress arch effect are disintegrated, so as to realize efficient unclogging of the ore pass. This study provides theoretical support and an engineering paradigm for the treatment of adhesion hang-up in high ore pass.

为了解决高矿道中颗粒颗粒的黏附挂起问题，本研究结合了现场调查、粒度统计和颗粒间黏附力学表征。通过微观结块机理与宏观结块条件耦合的多尺度分析，揭示了矿道悬吊的基本力学本质。提出了高效的疏通技术，并完成了工程应用。结果表明：颗粒颗粒的接触和粘附力学行为受颗粒级配的显著控制，法向接触力Fn、切向接触力Fs和毛细桥力Fc均随粒径的增大而增大，其中相似粒径组合下Fn、Fs和Fc的急剧增大是导致挂机的核心原因。接触角φ和颗粒级配作为胶粘剂平衡的协调控制参数。垂直（ϕ = 90°）接触和水平（ϕ = 0°）接触导致正常胶粘剂和切向胶粘剂分别因颗粒重量和粒径的差异而失效。细粒颗粒容易因团聚而出现持续挂起现象，在一定范围内调整矿道直径D、倾斜度α和颗粒高度H基本无效。粗颗粒通过消除应力拱、增大载荷和自重流优势，即增大α、D和H可以降低矿道悬吊风险，从而保持矿道的非阻塞状态。通过爆破技术，消除了矿槽的结块和应力拱效应，实现了矿槽的高效疏通。该研究为高溜井黏附悬吊的治理提供了理论支持和工程范例。

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引用次数: 0

Study on deformation and failure laws and differentiated control of surrounding rock in the return air entry of extremely close distance lower seam 极近距离下煤层回风巷道围岩变形破坏规律及差异化控制研究

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-07 DOI: 10.1016/j.engfailanal.2026.110557

Xiaofei Guo, Wenbo Zhang, Xiongxiong Jin, Kunlin Yang, Yinwei Wang, Yushan Liu

Stability control of the surrounding rock in development roadways of extremely close-distance lower coal seams is a crucial prerequisite for safe mining in underground coal mines. This study aims to reveal the deformation and failure mechanisms of the surrounding rock in such roadways, taking the extremely close-distance No. 9 and No. 11 coal seams in Dianye No. 1 Mine as the research object. It elucidates the response mechanisms and failure patterns of roadways under such complex mining-induced stresses. The results indicate that the return airway of the No. 11 coal seam is primarily influenced by the mining of the No. 9 coal seam working face and its own excavation. In contrast, the mining of the working face within the same coal seam, due to the presence of protective coal pillars along the roadway, exerts a certain pressure-relief and protective effect on the corresponding roadway section. The study further reveals the evolutionary pattern of the plastic zone morphology in the surrounding rock and clarifies the correlation between stress variations and the plastic zone. The lateral pressure coefficient dominates the failure mode of the surrounding rock, while the magnitude of the principal stress and the strength of the rock mass jointly regulate the extent of failure. The deflection angle of the principal stress directs the propagation path of the plastic zone. A differentiated support design based on the stress zones of the surrounding rock is proposed. Under remnant coal pillars, a trapezoidal roadway section with rock bolting, mesh, and cable support is adopted to utilize the self-supporting capacity of the surrounding rock and the structural characteristics of the strata. In high-stress environments under goaf areas, a arched roadway section with combined support of “rock bolting, mesh, cable, beam, and U-shaped steel supports” is implemented.

极近距离下煤层开发巷道围岩稳定性控制是地下煤矿安全开采的重要前提。本研究以电业1矿距离极近的9号、11号煤层为研究对象，旨在揭示此类巷道围岩变形破坏机理。阐明了巷道在复杂采动应力作用下的响应机制和破坏模式。结果表明：11号煤层回采巷道主要受9号煤层工作面回采及自身开挖的影响。而同一煤层内工作面开采，由于沿巷道存在保护煤柱，对相应的巷道段起到一定的卸压保护作用。研究进一步揭示了围岩塑性区形态演化规律，阐明了应力变化与塑性区的相关性。侧压力系数主导围岩破坏模式，主应力大小和岩体强度共同调节破坏程度。主应力的挠度角指导塑性区的传播路径。提出了一种基于围岩应力区的差异化支护设计方法。在残余煤柱下，采用锚杆支护、网眼支护、锚索支护的梯形巷道断面，充分利用围岩的自支护能力和地层的结构特点。在采空区高应力环境下，采用“锚杆、网、索、梁、u型钢支撑”组合支护的拱式巷道断面。

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引用次数: 0

Fatigue endurance of rib-to-deck welded joint in orthotropic steel deck panel 正交各向异性钢甲板肋-甲板焊接接头的疲劳耐久性

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-06 DOI: 10.1016/j.engfailanal.2026.110553

Kirill Golubiatnikov , Eva Schmidova , Pavel Ryjacek , Stanislav Hracov , Shota Urushadze , Filip Klejch

This study presents fatigue, fractography, and numerical analyses of a prefabricated orthotropic steel deck panel that had been in service on a real bridge before undergoing a fatigue laboratory test. The study focused on rib-to-deck welded joints executed as intermittent one-sided fillet welds.

Fractographic and fatigue analyses identified four typical crack types: “toe-rib”, “root-weld”, “root-deck” and “toe-deck”. The latter two types occurred only under loading parallel to the rib web, while the “root-weld” crack type was likely associated with a significant transverse shear stress component. The results indicate that the fatigue endurance of these joints is highly sensitive to shear stress. A proposed threshold for the necessity of considering shear stress influence is shear-to-normal stress ratio of 0.2 and 0.1 for the Nominal Stress and Hot Spot Stress methods, respectively. Two cracks were initially oblique toward the toe, potentially linked to grain coarsening in the heat-affected zone.

Mean reference fatigue strengths were 93 MPa for the Nominal Stress and 108 MPa for the Hot Spot Stress methods, with guaranteed characteristic values of 69 MPa and 86 MPa. Considering shear stress influence as a reduction factor for the reference characteristic value for normal stress proved ineffective.

本研究介绍了预制正交各向异性钢桥面板的疲劳、断口学和数值分析，该桥面板在进行疲劳实验室测试之前已在真实桥梁上使用。该研究的重点是肋板与甲板之间的焊接接头，这些焊接接头是间歇性的单边角焊缝。断口学和疲劳分析确定了四种典型的裂纹类型：“趾肋”、“根焊缝”、“根甲板”和“趾甲板”。后两种类型只发生在平行于肋腹板的荷载下，而“根焊”裂纹类型可能与显著的横向剪应力分量有关。结果表明，节理的疲劳耐久性对剪切应力高度敏感。对于名义应力和热点应力方法，考虑剪应力影响必要性的建议阈值分别为剪应力-正应力比0.2和0.1。两个裂缝最初是斜向脚趾的，可能与热影响区的晶粒变粗有关。名义应力法和热点应力法的平均参考疲劳强度分别为93 MPa和108 MPa，保证特征值分别为69 MPa和86 MPa。将剪应力影响作为法向应力参考特征值的折减因子被证明是无效的。

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引用次数: 0

Improved aluminum alloy gusset joint for single-layer reticulated shells: Failure behavior under single and combined loading conditions 改进的单层网壳铝合金扣板节点：在单一和组合载荷条件下的破坏行为

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-06 DOI: 10.1016/j.engfailanal.2026.110548

Haifeng Yang , Fukun Li , Bing Li , Qingmei Yang , Wei Chai , Jiewen Hong , Zhi Li

Traditional aluminum alloy gusset (TR-AAG) joints exhibit limited mechanical efficiency because load transfer relies exclusively on the upper and lower cover plates, while the beam web does not effectively participate in force transmission. This study introduces an improved aluminum alloy gusset (IM-AAG) joint incorporating shear connectors and a hollow hexagonal prism to optimize the load-transfer path. A finite element model, validated against existing experimental data, was employed to compare the structural performance of IM-AAG and TR-AAG joints. Parametric analyses were conducted to quantify the effects of key design variables, including the number of web bolts, bolt-hole clearance, bolt pretension, and the thicknesses of the shear connector and cover plate. The mechanical response of the IM-AAG joint was further examined under axial loading, pure bending, pure shear, and combined bending-axial and bending-shear conditions. An analytical moment-rotation model was also developed to predict the global rotational behavior of the joint. The results show that the IM-AAG joint exhibits pronounced enhancements in initial bending stiffness and ultimate flexural capacity. The addition of the hollow prism and shear connectors effectively suppresses bolt slip and mitigates web buckling, promoting a more ductile and progressive failure mode. Increasing the cover plate thickness and bolt quantity further improves flexural performance. Under combined bending-axial loading, axial compression reduces flexural resistance; however, this adverse effect is alleviated by the shear connectors. Overall, the proposed joint configuration and analytical model offer a robust and practical basis for the design and optimization of aluminum alloy joints in spatial structural applications.

传统的铝合金扣板（TR-AAG）节点机械效率有限，因为荷载传递完全依赖于上下盖板，而梁腹板不能有效地参与力传递。为了优化载荷传递路径，提出了一种改进的铝合金扣板（IM-AAG）节点，该节点结合了剪切连接件和中空六角形棱镜。采用有限元模型对IM-AAG和TR-AAG节点的结构性能进行了比较，并与已有的实验数据进行了验证。进行参数分析以量化关键设计变量的影响，包括腹板螺栓数量、螺栓孔间隙、螺栓预紧力以及剪切连接件和盖板的厚度。进一步研究了IM-AAG节点在轴向加载、纯弯曲、纯剪切、弯曲-轴和弯曲-剪切组合条件下的力学响应。为了预测关节的整体旋转行为，还建立了解析力矩-旋转模型。结果表明：IM-AAG接头的初始抗弯刚度和极限抗弯承载力均有显著提高；空心棱柱和剪切连接件的加入有效地抑制了螺栓滑移，减轻了腹板屈曲，促进了更具延展性和渐进式的破坏模式。增加盖板厚度和螺栓数量进一步提高了抗弯性能。在弯-轴联合加载下，轴压降低了抗弯阻力；然而，这种不利影响被剪切连接件所缓解。总体而言，所提出的节点构型和分析模型为空间结构应用中铝合金节点的设计和优化提供了坚实的实用依据。

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引用次数: 0

Blending hydrogen in existing natural gas pipelines: Impact of reduced JR-Curve slope on the pipeline integrity 现有天然气管道配氢：减小jr曲线斜率对管道完整性的影响

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-06 DOI: 10.1016/j.engfailanal.2025.110517

Mariano A. Kappes , Nicolas O. Larrosa , Marcos A. Bergant , Teresa E. Perez

Exposure to gaseous hydrogen decreases the fracture toughness, ductility and fatigue life of pipeline steels. Additionally, it reduces the material tearing resistance, or slope of the J-integral vs. crack growth resistance (J_R) curve. It is known that the reduction in fracture toughness decreases the critical crack size and the estimated failure pressure of hydrogen pipelines, compared to inert environments, like natural gas. The objective of this paper is to explore and quantify, for the first time, the effect of the J_R-Curve Slope on failure pressure and critical crack size, by conducting Level 3 crack assessments according to API 579-1/ASME FFS-1 international code. Upper and lower bound values for the tearing resistance in inert environment and in gaseous hydrogen were obtained from a literature review. The literature was reviewed to obtain true-stress–strain data of pipelines steels, required for constructing material specific failure assessment lines (FALs). The use of the generic FAL proposed in API 579-1/ASME FFS-1 international code resulted in an error less than 10 % in the estimated failure pressure, when compared to material specific FAL. The tearing resistance of the material had a significant effect on the estimated failure pressure, up to 26 % larger than the value obtained with a Level 2 assessment, for the set of pipe and crack geometry parameters chosen in this paper. Such larger level 3 failure pressure cannot be credited in hydrogen service, due to the flatter J_R curve and the risk of subcritical cracking. Hence, there is a double penalty of hydrogen blending in pipeline failure pressure, it decreases because K_IH < K_IC and the reserve safety factor is lost. The effect of tearing resistance on critical crack size and in crack detection limits during hydrotests were discussed and quantified in this paper. It is shown that the tearing resistance decreases the crack detection efficiency during hydrotests, so that it is possible that a pipeline that just passed a hydrotest at a stress level of 100 % of the specified minimum yield strength (SMYS) could have defects with a size larger than critical in hydrogen service at 72 % SMYS.

暴露于气态氢会降低管道钢的断裂韧性、延展性和疲劳寿命。此外，它还降低了材料的撕裂阻力，或j积分与裂纹扩展阻力（JR）曲线的斜率。众所周知，与惰性环境（如天然气）相比，断裂韧性的降低降低了氢气管道的临界裂纹尺寸和估计失效压力。本文的目的是通过根据API 579-1/ASME FFS-1国际规范进行三级裂缝评估，首次探索和量化jr曲线斜率对破坏压力和临界裂纹尺寸的影响。在惰性环境和气态氢环境下，通过文献综述得到了抗撕裂性能的上下界值。为了获得构建材料特定失效评估线（FALs）所需的管道钢的真应力-应变数据，对文献进行了回顾。与特定材料的FAL相比，使用API 579-1/ASME FFS-1国际规范中提出的通用FAL导致估计失效压力的误差小于10%。对于本文选择的管道和裂纹几何参数集，材料的抗撕裂性对估计的失效压力有显著影响，比用2级评估获得的值大26%。由于JR曲线较平坦，并且存在亚临界开裂的风险，因此在氢气应用中不能使用如此大的3级失效压力。因此，在管道失效压力中存在混氢的双重惩罚，由于KIH <； KIC和储备安全系数的损失而降低。本文讨论并量化了水力试验中抗撕裂性对临界裂纹尺寸和裂纹检测极限的影响。结果表明，抗撕裂性降低了水试时的裂纹检测效率，因此，刚通过水试的管道，在规定的最小屈服强度（SMYS）的100%应力水平下，有可能出现尺寸大于临界尺寸的缺陷，在72% SMYS的氢气服务中。

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引用次数: 0

Investigation of asphalt concrete damage under the combined action of freeze-thaw and load using DIC-CT method 用DIC-CT法研究冻融与荷载共同作用下沥青混凝土的损伤

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-05 DOI: 10.1016/j.engfailanal.2026.110535

Hengzhen Li , Huining Xu , Yiqiu Tan , Hongliang Qian

Freeze-thaw (F-T) and vehicle load are the main external forces acting on asphalt pavement in cold regions. Their concurrent action inflicts severe pavement damage, yet existing research has largely overlooked their combined impact, hampering a comprehensive understanding of asphalt concrete’s damage characteristics under combined F-T and load (F-T-L) conditions. Therefore, this study employed a custom-designed F-T-L testing device to simulate asphalt pavement damage scenarios. Coupling the digital image correlation method (DIC) with computed tomography technology (CT), we meticulously tracked the strain evolution within cross-sectional images of asphalt concrete samples. By comparing the strain distribution and development under F-T-L and F-T cycles, the influence of load on the deterioration of asphalt concrete under F-T cycles was clarified. The strain images of the sectional image of the specimen intuitively show that the area rich in void and the mortar interface were vulnerable areas, and with the continuous application of external forces, the strain level increased and the damage progressed unevenly. The differences in strain distribution under F-T-L and F-T underscore that F-T action primarily drives expansive deformation in asphalt concrete, while load intensifies the deformation, introducing damage gradients, and augmenting damage non-uniformity, especially under high load levels. Our study not only uncovers the intricate interplay between F-T and load but also provides critical insights for enhancing pavement durability in frigid climates.

冻融和车辆荷载是作用在寒冷地区沥青路面上的主要外力。它们的共同作用造成了严重的路面损伤，然而现有的研究在很大程度上忽略了它们的综合影响，阻碍了对混合荷载和荷载条件下沥青混凝土损伤特征的全面理解。因此，本研究采用定制的F-T-L试验装置模拟沥青路面损伤情景。将数字图像相关方法（DIC）与计算机断层扫描技术（CT）相结合，对沥青混凝土样品的截面图像中的应变演化进行了细致的跟踪。通过对比F-T- l和F-T循环下的应变分布和发展，阐明荷载对F-T循环下沥青混凝土劣化的影响。试件截面图像的应变图像直观地显示，孔隙丰富的区域和砂浆界面为脆弱区域，且随着外力的不断施加，应变水平增大，损伤进展不均匀。F-T- l和F-T作用下的应变分布差异表明，F-T作用主要驱动沥青混凝土的膨胀变形，而荷载作用则加剧变形，引入损伤梯度，增加损伤不均匀性，特别是在高荷载水平下。我们的研究不仅揭示了F-T和荷载之间复杂的相互作用，而且为提高寒冷气候下的路面耐久性提供了重要的见解。

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引用次数: 0

Notch sensitivity of impact toughness in Ti-6Al and Ti-8Al alloy Ti-6Al和Ti-8Al合金冲击韧性的缺口敏感性

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-05 DOI: 10.1016/j.engfailanal.2026.110540

Hanbo Weng , Qian Wang , Daokui Xu , Sensen Huang , Jianke Qiu , Jiafeng Lei , Rui Yang , Yingjie Ma

Notches are integral features in titanium alloy components that fundamentally govern their in-service performance. As a key alloying element, Al significantly enhances the strength and alters the deformation mechanisms of titanium alloys. This study investigates the influence of Al content and notch geometry on the impact toughness and deformation mechanisms of Ti-6Al and Ti-8Al alloy, while the Ti₃Al-α₂ phase in Ti-8Al alloy was also generated. To elucidate the underlying mechanisms of the toughness difference between U-notched and V-notched specimens, a combined experimental and finite element simulation approach was employed. The results indicate that U-notched specimens consistently exhibited marginally higher impact toughness than their V-notched counterparts across the Al compositions. A larger plastic zone in U-notched versus V-notched specimens was demonstrated by finite element analysis, thereby showing the higher impact toughness. The distinct mechanical responses of U-notched and V-notched specimens in Ti-6Al, Ti-8Al and Ti-8Al-α₂ alloy were manifested by differences in crack path tortuosity, dislocation distribution, slip activities and deformation twinning. Furthermore, an additional intragranular deformation disparity was identified in Ti-8Al. The study of impact toughness in U-notched and V-notched Ti-Al alloys provides a basis for predicting the failure of notched structures under dynamic loads and for guiding safety design, thereby enhancing service reliability and impact resistance.

缺口是钛合金部件中不可或缺的特征，从根本上决定了其使用性能。Al作为关键合金元素，能显著提高钛合金的强度，改变其变形机制。本研究考察了Al含量和缺口几何形状对Ti-6Al和Ti-8Al合金冲击韧性和变形机制的影响，同时Ti-8Al合金中也产生了Ti3Al-α2相。为了阐明u形切口和v形切口试样韧性差异的潜在机制，采用了实验和有限元模拟相结合的方法。结果表明，在不同的Al组分中，u形缺口试样的冲击韧性均略高于v形缺口试样。有限元分析结果表明，u形缺口比v形缺口具有更大的塑性区，因此具有更高的冲击韧性。在Ti-6Al、Ti-8Al和Ti-8Al-α2合金中，u形缺口和v形缺口试样的不同力学响应表现为裂纹路径弯曲度、位错分布、滑移活动和变形孪晶的差异。此外，在Ti-8Al中发现了额外的晶内变形差异。研究u型缺口和v型缺口钛铝合金的冲击韧性，为缺口结构在动载荷作用下的失效预测和指导安全设计提供依据，从而提高其使用可靠性和抗冲击性。

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引用次数: 0

Study on stability and failure modes of long-narrow deep excavations 长窄深基坑稳定性及破坏模式研究

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-05 DOI: 10.1016/j.engfailanal.2026.110534

Shouhua Liu , Yiding Zhao , Hua Zhu , Yanning Du

Stability analysis and failure modes of basal heave in deep excavations are crucial, as they are essential for determining the safety factor in design. In this study, an algorithm based on upper bound finite element theory and adaptive technology is presented, which can characterize the failure modes of basal heave in long-narrow deep excavations. The results demonstrate that when the width-to-depth ratio is less than or equal to 2, the effect of excavation width should be considered in the basal heave stability analysis. The failure modes of long-narrow deep excavations manifest as an arc expansion pattern. Furthermore, the safety factors calculated by the proposed method are more reasonable. The research results can serve as a reference for analyzing basal heave stability and optimizing the design of supporting structures for long-narrow deep excavations.

深基坑基础隆起的稳定性分析和破坏模式是确定深基坑设计安全系数的关键。本文提出了一种基于上界有限元理论和自适应技术的长窄深基坑底鼓破坏模式表征算法。结果表明，当宽深比小于等于2时，基坑开挖宽度对基坑底鼓稳定性的影响应考虑在内。长窄深基坑的破坏模式表现为圆弧扩展模式。采用该方法计算的安全系数更为合理。研究结果可为长窄深基坑基坑底鼓稳定性分析及支护结构优化设计提供参考。

引用次数: 0

Research on wheel-rail coupling resonance and ballastless-track interlayer damage mechanism at 400 km/h speed under temperature gradients 温度梯度下400 km/h速度下轮轨耦合共振及无砟轨道间层损伤机理研究

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-05 DOI: 10.1016/j.engfailanal.2026.110538

Chaozhi Ma , Yong Wei , Weitao Cui , Shuxin Zhao , Liang Gao

China plans to operate high-speed railways at speeds above 400 km/h. However, the coupling mechanism between temperature gradients (TGs) in ballastless tracks and wheel-rail dynamic interactions under such high-speed conditions remains unclear. This research establishes a ballastless track-vehicle dynamic interaction model and a cohesive damage analysis model for ballastless tracks under TGs. These models fully consider the TG-induced warping deformation of track slabs and the nonlinear slapping behavior between the slab and the baseplate. The warping deformation of a track slab was quantified using the chord measurement method, and the spatial vibration changes were evaluated during on-site vehicle operations under TGs, thereby confirming the models’ reliability. The study examines how TGs induce the wheel-rail coupling resonance and exacerbate ballastless-track interlayer damage at 400 km/h. Results indicate that under positive TGs, slab corners exhibit higher acceleration but lower deformation than the center. Furthermore, the downward transmission of train dynamic loads leads to interlayer contact-force concentration and vibration-energy accumulation at slab corners and edges, raising damage risks. Severe TGs lower the P2 resonance mode frequency, shifting the critical speed for wheel-rail coupling resonance forward to around 400 km/h and intensifying dynamic interactions under the eccentric wheel excitation. Moreover, the interlayer damage risk, driven by the combined effects of eccentric wheel excitations and TGs, exhibits a non-monotonic dependence on running speed: it initially increases, peaks around 400 km/h, and then decreases. This work provides a theoretical foundation for dynamic design and damage mitigation in ballastless track systems for 400 km/h high-speed railways.

中国计划运营时速超过400公里的高铁。然而，在这种高速条件下，无砟轨道温度梯度与轮轨动力相互作用之间的耦合机制尚不清楚。建立了tg作用下无砟轨道-车辆动力学相互作用模型和无砟轨道内聚损伤分析模型。这些模型充分考虑了tg引起的轨道板翘曲变形和轨道板与底板之间的非线性拍打行为。采用弦线测量法对轨道板翘曲变形进行了量化，并对车辆在tg作用下现场运行时的空间振动变化进行了评估，从而验证了模型的可靠性。研究了在400km /h高速下，tg如何诱发轮轨耦合共振并加剧无砟轨道间层损伤。结果表明：在正tg作用下，板坯角部的加速度大于中心，但变形较小；此外，列车动载荷的向下传递导致了层间接触力集中和板坯角部和边缘的振动能积累，增加了损伤风险。严重的tg降低了P2共振模态频率，使轮轨耦合共振的临界速度前移至400 km/h左右，并加剧了偏心轮激励下的动力相互作用。此外，在偏心轮激励和tg的共同作用下，层间损伤风险与车速呈非单调关系，初始增大，在400 km/h左右达到峰值，随后减小。为400km /h高速铁路无碴轨道系统的动态设计和损伤缓解提供了理论依据。

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引用次数: 0

Microstructure evolution and wear failure mechanism in laser powder bed fused Cobalt-Based coating on High-Speed train brake Discs: The Role of interlayer rotation angle 高速列车制动盘激光粉末床熔覆钴基涂层组织演变及磨损失效机理：层间旋转角度的作用

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis

Pub Date : 2026-01-05 DOI: 10.1016/j.engfailanal.2026.110539

Huoping Zhao , Yang Zhao , Ajin Wang , Mingxue Shen , Yelong Xiao

High-speed train brake discs are prone to wear during service. To address this failure, cobalt-based alloy coatings were fabricated on brake disc surfaces via laser powder bed fusion (LPBF), with a focus on the effect of interlayer rotation angle (30°, 67°, 90°) on microstructure evolution, mechanical properties, and wear mechanisms. Results indicate that rotation angle significantly influences grain morphology and texture strength: larger angles reduced equiaxed grain content and decreased Vickers hardness, though all coatings remained harder than the substrate. Crucially, wear loss showed a non-monotonic relationship with rotation angle, reaching a minimum at 30° due to optimized micromechanical properties. The ratio H/Er and H³/Er², rather than Vickers hardness alone, were identified as key indicators controlling wear behavior. The coatings exhibited abrasive, third-body, and oxidative wear, but at 30° displayed a 74.8% reduction in wear compared to the substrate, highlighting its potential for preventing in-service failure under extreme conditions such as requent and emergency braking.

高速列车制动盘在使用过程中容易磨损。为了解决这一问题，通过激光粉末床熔合（LPBF）在刹车盘表面制备了钴基合金涂层，重点研究了层间旋转角度（30°，67°，90°）对组织演变，力学性能和磨损机制的影响。结果表明，旋转角度对晶粒形貌和织构强度有显著影响：较大的旋转角度降低了等轴晶粒含量，降低了维氏硬度，但所有涂层仍比基体硬。至关重要的是，磨损损失与旋转角度呈非单调关系，由于优化的微机械性能，在30°时达到最小。与单纯的维氏硬度相比，H/Er和H3/Er2是控制磨损行为的关键指标。涂层表现出磨蚀性、第三体磨损和氧化磨损，但在30°时，与基材相比，磨损减少了74.8%，突出了其在防止频繁制动和紧急制动等极端条件下的使用故障的潜力。

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