Abstract
A comprehensive failure analysis was carried out for a crack appearing in the welded structure of an aluminum alloy body traction beam in a service metro vehicle. The fracture composition analysis reveals the products remaining after the reaction between the external corrosive medium and the material. A three-dimensional finite element model of the welded area of the traction beam was further established to simulate the high residual tensile stress present in the welded area. Based on the dynamic stress testing, it was found that the external loads had little effect on their crack growth. A series of analyses based on material properties, microstructure, fracture morphology and residual stresses identified stress corrosion as the leading cause of crack growth failure. Finally, a new structural repair program is proposed, and the reliability of the new structure in service life is verified by comparison, avoiding catastrophic fracture accidents in the service structure.
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