Engineering Failure Analysis最新文献

{"title":"Experimental study on the mechanical and deformation characteristics and failure mode of vertical combined frame-type retaining structure","authors":"Yan Xu,&nbsp;Yong Hao,&nbsp;Congwen Peng,&nbsp;Yang Tang,&nbsp;Xuan Wang,&nbsp;Zexi Chen","doi":"10.1016/j.engfailanal.2025.110448","DOIUrl":"10.1016/j.engfailanal.2025.110448","url":null,"abstract":"<div><div>For foundation pit projects with complicated surrounds and constrained construction areas, this study suggests a vertically combined frame-type retaining structure (VCFRS) to improve construction efficiency. This retaining structure features a flexible plan layout and easily adjustable structural stiffness. The impacts on retaining structures of variables such as the number of connecting beams (<em>n</em>) and the space between connecting beams (<em>B</em>) were examined through laboratory model tests. The experimental results show that, during excavation, the VCFRS exhibit a “pile-braced” deformation pattern, with the support effect influenced by the number of connecting beams, the position of the second connecting beam, and the excavation depth. Compared with single-row piles, the VCFRS not only alter the distribution pattern of pile bending moments, flattening their profile, but also reduce the peak bending moment of the pile. With increasing excavation depth, the active earth pressure behind the rear pile (RP) transitions from linear to a piece-wise linear pattern, the passive earth pressure in front of the RP decreases, and the passive earth pressure in front of the front pile (FP) increases. The VCFRS demonstrates an overturning failure mode during the testing, and as <em>B</em> increases, the retaining piles’ rotation point progressively moves upward. In the VCFRS design, in addition to considering factors such as <em>n</em> and <em>B</em>, it is recommended to reinforce the soil between the front and rear piles, as well as the joints between connecting beams and retaining piles.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110448"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788843","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}

{"title":"Failure mechanisms and reliability assessment of MgO-based TMR sensors under harsh electrical and environmental conditions","authors":"Guanying Wang,&nbsp;Xianfeng Liang,&nbsp;Yuxin Cheng,&nbsp;Yixue Wang,&nbsp;Yang Lu,&nbsp;Dengfeng Ju,&nbsp;Jinghong Guo","doi":"10.1016/j.engfailanal.2025.110473","DOIUrl":"10.1016/j.engfailanal.2025.110473","url":null,"abstract":"<div><div>This study presents a comprehensive long-term reliability evaluation of MgO-based TMR current sensors under combined electrical and environmental stress conditions representative of smart grid environments. We subjected packaged sensors to a suite of accelerated stress tests (stepwise voltage ramp-to-breakdown, high-temperature operating life, biased damp-heat exposure, thermal cycling, electrostatic discharge, and surge events). We continuously monitored the sensors’ electrical output during each test and complemented these measurements with infrared thermography and post-test failure analysis. Each stress produced a distinct failure signature. Excessive voltage stress induced an abrupt dielectric breakdown of the MgO tunnel barrier, resulting in a sudden drop in the device’s resistance and localized melting. Under combined high-temperature and high-humidity stress, moisture ingress caused a gradual increase in leakage current, eventually leading to a short-circuit through edge-initiated pinholes. In contrast, high-temperature operation alone caused only modest parameter drift with no catastrophic failures, indicating good intrinsic thermal stability of the magnetic tunnel junction (MTJ) stack. Thermal cycling primarily affected the package interconnects, while the MTJ devices remained intact. On-chip protection clamps largely absorbed fast transient surges; in some cases, the clamps themselves short-circuited yet still successfully protected the MTJ core. Overall, device reliability is governed by the integrity of the MgO barrier and the robustness of the packaging and protection circuitry. Electrical overstress and moisture emerged as the dominant failure drivers, whereas elevated temperature and thermomechanical cycling induced much slower and more manageable degradation. This analysis correlates each stressor with its underlying failure mechanism and outlines practical mitigation measures. Key recommendations include voltage derating, robust transient-clamping circuitry, moisture-resistant packaging, high-temperature-stable MTJ stacks with an appropriate annealing burn-in process, and a compliant interconnect design. Implementing these measures will enable durable, field-ready TMR sensors and facilitate predictive maintenance. To the best of our knowledge, this study presents the first comprehensive reliability evaluation of TMR sensors under combined stress conditions. It addresses a critical knowledge gap and offers actionable design guidelines for robust sensor deployment.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110473"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837491","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}

{"title":"Seismic failure analysis and risk assessment framework for masonry-slab arch bridges considering comprehensive seismic intensity measures","authors":"Si-Qi Li,&nbsp;Wen-Bo Chu","doi":"10.1016/j.engfailanal.2025.110493","DOIUrl":"10.1016/j.engfailanal.2025.110493","url":null,"abstract":"<div><div>Seismic failure and risk assessment strategies for bridges are crucial for evaluating the disaster resistance capability of urban and rural infrastructure. However, methods and strategies applicable to seismic risk and failure estimation of masonry-slab arch bridges (MSABs) are relatively lacking. A single seismic intensity estimation strategy is challenging to use to estimate seismic intensity accurately. To address this critical issue, this study considers multiple seismic intensity measures. A comprehensive strategy for estimating seismic intensity was proposed. By utilizing a comprehensive seismic intensity estimation model and equations, various ground motion parameters were analysed and compared, considering the monitoring records of nine stations with different spatial distributions (1467,246 earthquake accelerations) during the Wenchuan earthquake in China. A novel scale for estimating the fragility of MSABs is proposed by combining the comprehensive seismic intensity estimation method with the updated Chinese seismic intensity standard. The proposed method was used to estimate the fragility grade of 125 MSABs surveyed onsite. A seismic fragility prediction model for MSABs that incorporates logarithmic-linear fitting and optimized nonlinear estimation algorithms has been developed. The comparison results of the logarithmic-linear regression models indicate that the proposed model has high prediction accuracy for the FG1 level, with a goodness-of-fit of 0.762 and relatively low error, and a low prediction accuracy for the FG5 level, with a goodness-of-fit of 0.293. A three-dimensional numerical model of an MSAB was developed via three-dimensional numerical simulation technology. The earthquake failure and damage simulation of MSAB was conducted considering comprehensive seismic intensity measures. Considering the displacement demands, a dynamic time history comparison curve for the MSAB is generated. Incremental dynamic analysis (IDA) considering various innovative engineering demand parameters was performed. According to the Chinese bridge seismic design code and intensity standards, the drift limit of the numerical model is 0.1 m. The threshold values for seismic acceleration (capacity) in zones Ⅵ–XI are 2.0 m/s², 3.5 m/s², 5.0 m/s², 8.0 m/s², 15 m/s², and 30 m/s², respectively. A seismic failure cloud-map model for MSABs considering comprehensive seismic intensity measures was generated. According to the results of the method analysis and numerical simulation verification, the proposed failure and risk model can be effectively used to evaluate the seismic risk and failure modes of MSABs.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110493"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837837","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}

{"title":"Effect of hydrogen content on hydrogen embrittlement behavior and fracture mechanisms of SA508Gr.4N for nuclear reactor pressure vessel","authors":"Xin Dai ,&nbsp;Ruikai Yu ,&nbsp;Qing Dong ,&nbsp;Lijun Wang ,&nbsp;Ran Li ,&nbsp;Yuan Zhang ,&nbsp;Yaqiang Tian ,&nbsp;Liansheng Chen","doi":"10.1016/j.engfailanal.2025.110471","DOIUrl":"10.1016/j.engfailanal.2025.110471","url":null,"abstract":"<div><div>To investigate the effect of hydrogen content on the hydrogen embrittlement behavior of SA508Gr.4 N low-alloy steel for nuclear pressure vessels, this study analyzed the hydrogen desorption behavior in the steel via thermal desorption spectroscopy (TDS). Dynamic hydrogen charging combined with slow strain rate tensile (SSRT) tests were studied to evaluate the variations in mechanical properties and fracture characteristics. Furthermore, the initiation and propagation mechanisms of hydrogen-induced cracks were systematically characterized. The results demonstrated that the hydrogen charging current density had a significant effect on hydrogen desorption behavior: the hydrogen desorption rate and hydrogen content in steel increased with the increase of current density when the current density was below 10 mA/cm², beyond which it declined due to the initiation of hydrogen-induced cracking. Under the dynamic hydrogen charging slow strain rate tensile testing, the elongation exhibited a monotonic decrease from 24.3 % to 7.7 % as the current density increased from 0 mA/cm² to 30 mA/cm², while the hydrogen embrittlement susceptibility coefficient increased monotonically to 68.3 %. The fracture mode transitioned progressively from ductile fracture to intergranular brittle fracture. The presence of hydrogen preferentially drove crack initiation at grain boundaries and then propagated along martensitic laths and grain boundaries. This process weakened interfacial cohesion and reduced propagation energy barriers, thereby accelerating brittle fracture.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110471"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837833","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}

{"title":"Energy-fractal characterization and correlation of fracture behavior in pipeline girth welds","authors":"Xingfeng Liu ,&nbsp;Yongxin Xu ,&nbsp;Ying Zhen ,&nbsp;Jian Chen ,&nbsp;Guiyi Wu ,&nbsp;Yuguang Cao","doi":"10.1016/j.engfailanal.2025.110484","DOIUrl":"10.1016/j.engfailanal.2025.110484","url":null,"abstract":"<div><div>Girth welds constitute critical connecting components in pipeline systems, where their fracture behavior directly determines structural integrity. Conventional single-parameter characterization methods fail to simultaneously capture macroscopic energy absorption and fracture morphology evolution. This study proposes an energy-fractal dual-parameter framework integrating specific fracture energy and three-dimensional fractal dimension to systematically investigate X65 pipeline girth weld fracture behavior under varying stress triaxialities. Notched tensile specimens from base metal, weld metal, and heat-affected zones were tested. Specific fracture energy was quantified from load-displacement curves, while fractal dimensions were calculated from laser-scanned fracture surfaces using box-counting algorithms. Results demonstrate that heat-affected zones exhibit superior toughness under low stress triaxiality, whereas weld metal remains the weakest region across all notch configurations. Fractal dimension decreases monotonically with increasing stress concentration, indicating progressive transition from tortuous to planar crack propagation. A cubic polynomial regression established the quantitative relationship between energy dissipation and surface complexity, revealing the intrinsic coupling mechanism. This paper provides a novel pathway for failure analysis of girth welds and establishes a theoretical basis for energy-based integrity prediction.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110484"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837832","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}

{"title":"Fatigue behavior analysis on the bolt connecting the head-cover and stay ring in pumped storage unit: Part I − fatigue test","authors":"Qiang Zhao ,&nbsp;Tianyu Zhang ,&nbsp;Kenan Du ,&nbsp;Keyuan Wang ,&nbsp;Qingyuan Song ,&nbsp;Yongyao Luo","doi":"10.1016/j.engfailanal.2025.110490","DOIUrl":"10.1016/j.engfailanal.2025.110490","url":null,"abstract":"<div><div>This paper aims to investigate the fatigue behavior analysis on the bolt connecting the head-cover and stay ring in pumped storage unit by fatigue test, to ensure the long-term safe operation of key components. Firstly, the chemical composition and properties of the bolt material 34CrNi3Mo are analyzed to reveal its characteristics. Furthermore, the test schemes for the bolt material and the head-cover bolt specimens are formulated, forming a material-component progressive test system. Finally, fatigue tests are conducted under simulated operating conditions with variable alternating loads, and the test results are comprehensively analyzed. The results show that: 1) The microstructure of the bolt material is tempered sorbite, which has excellent comprehensive mechanical properties. 2) The fatigue limit of this material is determined to be 1017 MPa by using the Up-and-Down Methods. 3) The S-N curve of 34CrNi3Mo is established through the Grouping Method, providing a reliable basis for fatigue life prediction. 4) Fatigue cracks in head-cover bolts initiate at the thread root, a typical stress concentration area, and non-metallic inclusions in the material significantly accelerate crack propagation. This research deepens the understanding of the fatigue fracture mechanism of connecting bolts and provides technical support for the design, maintenance, and reliability improvement of pumped storage unit bolts.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110490"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880843","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}

{"title":"Dynamic interaction mechanism of deposit slope-tunnel system during heavy rainfall: insights from large-scale model experiments","authors":"Peiyu Deng ,&nbsp;Yongjie Zhang ,&nbsp;Xuefeng Ou ,&nbsp;Zongbao Yang ,&nbsp;Tao Hu","doi":"10.1016/j.engfailanal.2026.110528","DOIUrl":"10.1016/j.engfailanal.2026.110528","url":null,"abstract":"<div><div>The stability of deposit slope at tunnel portal declines rapidly under heavy rainfall, posing a serious threat to the tunnel safety. A large-scale rainfall simulation apparatus was carried out to investigate the behaviors of the deposit slope–tunnel system during heavy rainfall. Based on the similar theory, the moisture content variation characteristics, surface displacement, and the earth pressure and strain around tunnel were monitored and analyzed. The test results indicate that the deposit slope is highly sensitive to rainfall. After 60 min, parts of the slope approached saturation, with the moisture content reaching 24.5%. Furthermore, the presence of the tunnel significantly alters the seepage pathways within the slope, partially disrupting the hydraulic and mechanical continuity between the upper and lower sections. This leads to an increase in moisture content in the upper slope, which not only elevates the risk of landslides but also intensifies the interaction of the slope-tunnel system. The stress distribution within the slope–tunnel system exhibited strong compressive characteristics, with abrupt changes in stress and strain at the rock–soil interface. The maximum increase around tunnel near the interface reached 93.9% for stress and 149.2% for strain. These results clarified the interaction mechanisms of the slope–tunnel system under rainfall infiltration, offers valuable insights for mitigating similar hazards in engineering.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110528"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880847","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}

{"title":"Multi-hazard failure analysis of highway bridges under earthquake and blast loading","authors":"Souvik Biswas,&nbsp;Piyali Sengupta","doi":"10.1016/j.engfailanal.2025.110506","DOIUrl":"10.1016/j.engfailanal.2025.110506","url":null,"abstract":"<div><div>Highway bridges constitute an essential part of modern infrastructure and are vital to the national economy. However, in case of natural or man-made hazards, such as earthquakes and blasts, highway bridges are highly susceptible to partial or total failure, thereby disrupting the continuous transportation and emergency evacuation routes. An increased focus on blast-resilient design of structures has been observed after the WTC attacks in the USA. Highway bridges located in seismically active regions may also be the potential targets of accidental or malicious blast loading. Consequently, it has become paramount to predict the response of existing highway bridges, as well as to implement robust design principles to prevent a catastrophic failure during the occurrence of such events in the presence of the added risk of a seismic event. Therefore, a database of 153 research papers are accumulated from the investigations conducted by the researchers across the globe during 1950 to till date so as to explore the seismic and blast performance of highway bridges. Subsequently, a comprehensive review of the state-of-the-art on seismic and blast performance of typical highway bridges in the context of independent hazard scenario and multi-hazard scenario is presented in this research. This study encompasses the research outcomes from the experimental investigations, field tests, numerical simulations, development of fragility functions, application of artificial intelligence in the seismic and blast performance of new, deteriorated and retrofitted highway bridges under single hazard scenario as well as in conjunction with another hazard using multi-hazard concepts. This study highlights the substantive findings from the existing state-of-the art and the potential research gaps in the domain of multi-hazard failure analysis of highway bridges.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110506"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880850","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}

{"title":"Progressive collapse behavior of SMB floors: complete load-displacement response under various edge column loss scenarios","authors":"Jing-Zhou Zhang,&nbsp;Yuan-Zhi Ji,&nbsp;Ping Tan,&nbsp;Zhi-Wei Yu,&nbsp;Lei Xiao","doi":"10.1016/j.engfailanal.2025.110524","DOIUrl":"10.1016/j.engfailanal.2025.110524","url":null,"abstract":"<div><div>This study systematically investigates the progressive collapse resistance of floors in steel modular buildings (SMBs) under edge column loss scenarios. Three typical edge column types are considered based on the boundary conditions of the floor after column loss: general edge column (GEC), penultimate edge column (PEC), and corner column (CC). A total of 614 refined finite element models of the SMB floor were developed and analyzed until structural collapse. The effects of key parameters, including slab width, length‑width ratio, thickness, rebar ratio, beam section, and column section, were evaluated. Simplified calculation methods are proposed for the ultimate load-carrying capacity (ULCC), yield load-carrying capacity (YLCC), yield displacement, and ultimate displacement, enabling efficient prediction of the complete load‑displacement curve of the floor in different scenarios. It is found that the load‑displacement curve of SMB floor shows a bilinear behavior in all scenarios, but the post-yield strengthening of the curve is more significant in GEC loss. The ULCC-to-YLCC ratio of the floor varies from 1.3 to 3.0 for GEC loss, from 1.0 to 2.2 for PEC loss, and from 1.2 to 1.8 for CC loss. The ULCC of the floor in GEC and CC loss can be expressed as a function of the slab bending moment, beam tensile force, and beam bending moment. For PEC loss, the floor ULCC relative to that in GEC loss is influenced by the stiffness of columns, slabs, and beams. The ULCC-to-YLCC ratio of the floor in all scenarios can be determined by the slab width, slab length-to‑width ratio, slab span-to‑thickness ratio, slab rebar ratio, and beam span-to‑depth ratio.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110524"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921275","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}

{"title":"Influence of fused filament fabrication process parameters on the quasi-static mechanical behaviour and failure mechanisms of 316L stainless steel","authors":"J. Zenzerovic,&nbsp;F. Sordetti,&nbsp;A. Lanzutti,&nbsp;E. Salvati","doi":"10.1016/j.engfailanal.2026.110532","DOIUrl":"10.1016/j.engfailanal.2026.110532","url":null,"abstract":"<div><div>The emergence of fused filament fabrication (FFF) for metal printing has introduced a cost-effective alternative to traditional fusion-based metal additive manufacturing methods. Nevertheless, the highly inhomogeneous material microstructures resulting from this manufacturing technology seriously compromise its structural integrity performance. This study comprehensively investigates the influence of six key printing parameters – nozzle temperature, bed temperature, print speed, layer thickness, infill pattern, and infill percentage – on the quasi-static mechanical performance and dimensional accuracy of a 316L stainless steel produced via FFF. 316L stainless steel was selected as the focus material due to its widespread industrial relevance and early availability in filament form. A structured design of experiments (DOE) was implemented, followed by analysis of variance (ANOVA) and signal-to-noise (S/N) ratio analysis to assess both performance and consistency. Six material responses were evaluated: yield strength, ultimate tensile strength, stress and strain at break, toughness, and dimensional accuracy. Bed temperature was the most influential parameter, with the highest temperature of 120 °C enhancing interlayer bonding and thereby improving static mechanical properties and dimensional accuracy. The highest nozzle temperature of 250 °C provided moderate improvements in static mechanical performance, while increasing print speed to 40  mm/s improved deposition quality by reducing filament residence time and limiting binder degradation. Additionally, smaller layer thickness, line-based infill pattern, and full (100 %) infill further improved static mechanical properties by minimising interlayer voids and promoting efficient stress transfer. Hardness testing was performed to provide additional insight into the material’s mechanical response. Alongside, fractography and porosity analysis were carried out to characterise failure mechanisms and quantify internal defects, revealing that large printing-induced pores dominate failure and persist after sintering, directly influencing mechanical reliability. These findings provide insights into parameter-dependent trends and interlayer bonding quality, contributing to the optimisation of print conditions for enhanced mechanical reliability and reduced variability in metal FFF components.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"186 ","pages":"Article 110532"},"PeriodicalIF":5.7,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921287","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}