Failure Analysis Research Articles

Intricacies in the Failure Analysis of Integrated Capacitors

Intricacies in the Failure Analysis of Integrated Capacitors

Multi-scale analysis of ultimate bearing capacity in composite hull joints: failure mechanism and numerical simulation

ABSTRACT Progressive failure analysis method is the main method to analyse the ultimate bearing capacity and failure mode of composite structures. Multi-scale method can effectively reduce the dependence of damage mode and stiffness degradation analysis on material parameters. Based on the multi-scale method, from micro-scale to mesoscale and then to macro-scale, the equivalent modulus and equivalent strength of fibre bundles, single-layer laminates and multi-directional laminates were predicted respectively, and the prediction method of ultimate bearing capacity of large-scale composite structures from material level to structure level was constructed. The mechanical properties of standard composite materials and the ultimate bearing capacity of full-scale composite joints were tested respectively, and the ultimate bearing capacity and failure mode of L-joints were predicted by numerical method. The results show that the numerical simulation method based on multi-scale can accurately predict the ultimate bearing capacity and failure mode of large-scale joints of the hull.

Towards the Automation of Non-destructive Fault Recognition: Enhancement of Robustness and Accuracy Through AI Powered Acoustic and Thermal Signal Analysis in Time, Frequency- and Time-Frequency Domains

AbstractNon-destructive inspection and analysis techniques are crucial for quality assessment and defect analysis in various industries. They enable for screening and monitoring of parts and products without alteration or impact, facilitating the exploration of material interactions and defect formation. With increasing complexity in microelectronic technologies, high reliability, robustness and thus, successful failure analysis is essential. Machine learning (ML) approaches have been developed and evaluated for the analysis of acoustic echo signals and time-resolved thermal responses for assessing their ability for defect detection. In the present paper different ML architectures were evaluated, including 1D and 2D convolutional neural networks (CNNs) after transforming time domain data into the spectral- and wavelet domains. Results showed that 2D CNNs processing data in wavelet domain representation performed best, however at the expense of additional computational effort. Furthermore, ML-based analysis was explored for lock-in thermography to detect and locate defects in the axial dimension based on thermal emissions. While promising, further research is needed to fully realize its potential.

Selected Papers from the 49th International Symposium for Testing and Failure Analysis (ISTFA 2023)

Selected Papers from the 49th International Symposium for Testing and Failure Analysis (ISTFA 2023)

Failure Analysis of Y-Anchors of Hot Cyclone Refractory of Circulating Fluidized Bed Boilers

Failure Analysis of Y-Anchors of Hot Cyclone Refractory of Circulating Fluidized Bed Boilers

Horizontal analysis and longitudinal cohort study of chronic renal failure correlates and cerebral small vessel disease relationship using peak width of skeletonized mean diffusivity

Background and purposePeak width of skeletonized mean diffusivity (PSMD) is an MRI-based biomarker that may reflect white matter lesions (WML). PSMD is based on skeletonization of MR DTI data and histogram analysis. Both chronic renal failure (CRF) and WML may be affected by multisystemic small-vessel disorder. We aimed to explore the relationship between PSMD and estimated glomerular filtration rate (eGFR).MethodsFifty followed-up CRF patients matched for age, sex, hypertension and smoking status were enrolled and classified into a progressive group (n = 16) and stable group (n = 34) based on eGFR levels. Longitudinal and horizontal differences of PSMD were compared between the progressive and stable groups at the initial and follow-up time points. Pearson’s correlation was used for correlation of eGFR with PSMD and WML (per Fazekas scale score). ROC was used to measure the sensitivity of PSMD and WML score to changes of eGFR.ResultsAt the follow-up time point, PSMD of the progressive group was significantly higher than at the initial time point (p < 0.001), and PSMD of the progressive group was significantly higher than stable group (p < 0.001). PSMD and eGFR were significantly correlated. AUC curves explored that ΔPSMD (PSMD changes at the follow-up and initial time points) and follow-up PSMD was better for the classification of progressive and stable groups.ConclusionPSMD has significant correlation with eGFR, PSMD can reveal a close relationship between WML and CRF.

A systematic corrosion failure analysis of Li-ion powered hearing aids from various markets

Hearing aids (HA) are low-power electronic devices used worldwide. The ongoing trend in the HA industry has been to move towards Li-ion battery technology replacing conventional zinc-air batteries. The corrosion reliability of HA devices is a critical issue, due to their exposure to harsh user environments including body fluid contact, high humidity, and temperature. The combined effect of higher operating voltage (4.3 V) and design miniaturisation poses new risks for corrosion reliability. To fully understand the environmental reliability issues of the Li-ion powered HA, it is crucial to investigate field performance by conducting root cause failure analysis on the field-returned failed devices. This study investigated two different HA models (open vs. glued model). The analysis used a systematic FMEA-based approach to identify and understand failure modes, mechanisms, and potential causes using various analysis techniques (e.g., LOM, SEM&EDS, and ICP-OES). Furthermore, statistical analysis was conducted based on the repair data created by the global service centre to reveal the failure percentage, and time to failure of different components. Passive components, solder connections, and galvanic charging contact showed the highest failure percentages. The most common causes of corrosion failures were high levels of chloride ions, high humidity, flux residues, and insufficient coating protection.

Failure analysis and structural resilience of a masonry arch Bridge subjected to blast loads: The Case study, Halilviran Bridge

This study investigates the dynamic response of masonry bridges under blast-induced shock waves, focusing on the structural integrity and safety of these critical infrastructure components under extreme conditions. The research employs theoretical approaches to analyze the effects of blast-induced shock waves on masonry bridge structures. A comprehensive numerical simulation framework is developed using finite element analysis (FEA) to model the dynamic interactions between blast waves and the masonry materials. Key parameters, including the blast load intensity, duration, and distance from the blast source, are varied to assess their impact on bridge performance. The results reveal significant insights into the deformation patterns, stress distribution, and potential failure modes of masonry bridges under blast loading scenarios. The findings underscore the importance of incorporating blast resistance measures in the design and retrofitting of masonry bridges to enhance their resilience against explosive events. This study contributes to the advancement of safety standards and design guidelines for masonry bridge structures in the context of blast loading, providing valuable information for engineers, policymakers, and infrastructure managers.

Failure analysis and structural optimization of unequal-parameter metal bellows in resistance to bending and torsional composite deformation

In practical engineering applications, metal bellows are subjected to complex environmental conditions, and they usually deform under the combined effects of tension, bending and torsion. In this paper, the bending and torsion composite deformation of unequal parameter metal bellows arranged alternately by large wave and wavelet is studied. Firstly, the finite element model of metal bellows is constructed, and the finite element simulation analysis of its mechanical properties is carried out. Taking the simulation results as samples, the multi-objective structural optimization of unequal parameter metal bellows under the condition of bending and torsion composite deformation is carried out. Combined with the bending-torsion composite deformation test and fracture microscopic characterization, the bending-torsion composite deformation characteristics and fracture failure mechanism of equal-parameter metal bellows (EPMB) and unequal-parameter metal bellows (Un-EPMB) were compared and analyzed. The results show that under the same deformation conditions, compared with the EPMB, the elastic limit bending line displacement and elastic limit torsion angle displacement of Un-EPMB are increased by 52.94 %, and the bending and torsional stiffness are greatly improved, moreover, the alternating waveform arrangement led to relatively gradual stress transfer through the Un-EPMB during the bending-torsion composite deformation process, thereby reducing stress concentration. Thus, the Un-EPMB exhibited more favorable mechanical properties. Unlike in the EPMB, which underwent fracture along the grain boundary, the cracks in the Un-EPMB appeared in the middle layer and propagated to both sides in a wavelike pattern. The dimples were distributed in the middle layer of the fracture, which indicates ductile behavior.

Numerical analysis of duct wall failure in a prototype FAIDUS design-based generation IV SFR fuel subassembly under flow blockage accident

An ingenious prototype Fuel Assembly Inner DUct Structure (FAIDUS) design is conceptualized under the Generation IV safety philosophy to prevent large-scale corium pool formation following total coolant flow blockage accident. The early failure of the duct wall provides a built-in guideway for molten material relocation out of the core region, ensuring inherent safety robustness. Therefore, understanding the duct wall failure mechanism is critical for evaluating accident mitigation potential of the FAIDUS design. In this regard, a transient enthalpy-based multiphase computational model is developed to investigate the heat transfer and fluid flow behavior involved during the duct wall failure in 3-D domain. The numerical model is employed initially to simulate wall failure in the EAGLE ID1 in-pile test. The model results are validated against the in-pile test data. Subsequently, FAIDUS duct wall failure in a prototype fast reactor fuel subassembly (SA) is investigated employing the present model. The study reveals that the large heat flux from the molten pool to the duct is the main reason for the duct wall failure. The duct failure starts with an initial rupture across the corners of the hexagonal-shaped duct and progresses to total failure of the duct wall by the expansion of the rupture over the whole duct wall area with time. The outer hexcan wall sustains only minor thermal damage during the duct wall failure process. The present study explores the associated thermal-hydraulics, molten pool dynamics, crust formation behavior, and event sequences involved in duct wall failure in great detail. The simulation findings suggest that the FAIDUS SA design facilitates premature failure of the slim duct wall prior to the hexcan wall failure. This could potentially enable early discharge of the molten corium away from the core region, limiting the accident progress.

A Comprehensive Failure Analysis Approach Utilizing High-Resolution Targeted Patterns (HRTP) for ATPG Diagnosis Resolution Improvement, Test Coverage Resolution, and Further Fault Localization

A Comprehensive Failure Analysis Approach Utilizing High-Resolution Targeted Patterns (HRTP) for ATPG Diagnosis Resolution Improvement, Test Coverage Resolution, and Further Fault Localization

Failure Analysis of Skid Beam in Walking Beam Reheating Furnace of Hot Strip Mill

Failure Analysis of Skid Beam in Walking Beam Reheating Furnace of Hot Strip Mill

Failure analysis of a frangible cover made of short‐cut basalt fiber reinforced epoxy composites

AbstractThe frangible cover made of continuous fiber reinforced composites has become widely used structure for the new generation launch canisters. However, destroying the continuity of fibers is needed during the hand lay‐up process to make the frangible cover fail in predetermined patterns. In this article, composite frangible covers were fabricated with short‐cut basalt fiber reinforced epoxy(BF/Epoxy) composites instead of continuous fiber‐reinforced composite materials, reducing the strength redundancy in the local structure of the frangible covers. Tensile tests were firstly conducted on material samples to obtain the stress–strain characteristics of the short‐cut BF/Epoxy composites. The constitutive model and failure criterion of the short‐cut BF/Epoxy composites material were established. Then failure pressure and failure mode of the frangible covers were predicted by finite element method. Two frangible covers with different geometric parameter were fabricated and subjected to static bursting strength tests. The influence of structure parameter on the bursting pressure of the frangible cover was investigated in detail. it was found that the bursting pressure of the BF/Epoxy composite fragile cover can be tailored by adjusting the geometry size of the weak zones on surface of the cover. Meanwhile, Failure modes and the bursting pressure of the BF/Epoxy composite fragile covers are highly consistent with the predictions.Highlights A frangible cover made of the short‐cut basalt fiber reinforced epoxy(BF/Epoxy) composites was fabricated. The constitutive model and failure criterion were established based on the mechanical properties of the short‐cut BF/Epoxy composites. The static burst strength of the short‐cut BF/Epoxy composite frangible cover subjected to uniform pressure was investigated via both theoretical and experimental approaches. The short‐cut BF/Epoxy composite frangible cover eventually failed in accordance with the predetermined pattern. The simulation error of the failure pressure of the short‐cut BF/Epoxy composite frangible cover was less than 20%.

Failure analysis of erosion wear of the pipeline after 30° elbow by adsorbent particles

An adsorbent transport pipeline after a 30° elbow experienced premature perforation and leakage during service. The failure analysis was performed by means of morphology observation, damaged surface analysis and computational fluid dynamics (CFD) simulation. The results revealed that thickness thinning occurred only on the upper wall, and the severely thinned region exhibited a special striated groove morphology. The main cause of pipeline failure was attributed to erosive wear caused by adsorbent impacts on the wall. Due to the particle redistribution process under the action of multiple force fields in the small bending angle elbow, the straight pipeline after the elbow had a very complex inlet boundary condition, so that the particle concentration at the upper wall was substantially increased. Besides, the sliding motion of the particles on the wall surface was greatly intensified. Cutting deformation became the main form of erosion damage, which induced an alteration in the erosional morphology of the failed pipeline and the backwardness of the leakage site.

Modeling and analysis of cascading failures in multilayer higher-order networks

With the increasing application of network science, understanding the behavior of higher-order networks has become particularly important. Especially, the study of multilayer higher-order networks is significant for revealing the interdependence and higher-order interactions in complex systems. This paper proposes a mathematical framework to explore multilayer higher-order networks composed of multiple fully interdependent hypergraphs. Each hypergraph consists of the same number of nodes, and nodes between layers are connected one-to-one. By analyzing the cascading failures of multilayer hypergraphs under different topologies, we found that although the network sizes are the same in the steady state, different topological structures (such as star-like, tree-like, and chain-like) significantly affect the time required to reach a stable state, with the star-like topology reaching stability the fastest. Furthermore, we explored the impact of network parameters on the robustness of networks. We found that in multilayer homogeneous hypergraphs, the robustness of the network becomes stronger with an increase in the average hyperdegree or average hyperedge cardinality; in multilayer heterogeneous hypergraphs, the robustness of the network becomes more fragile as the power exponent increases. Finally, experimental results indicate that with the rise in the number of network layers, the network becomes more fragile.

Mechanism analysis of burn-up failure for needle roller bearing at high-speed gear in manual transmission

Adequate lubrication conditions of needle roller bearings are crucial for the normal operation of transmission. Addressing the burn-up and adhesion failures of needle roller bearings during transmission bench trials, two rigid body rotation physical models were developed to analyze and model the lubrication effect on the inner and outer surfaces of needle roller bearing. Through theoretical analysis and lubrication simulation, it was found that under the critical condition of d/D=0.553, the centrifugal force F on the outer ring surface of the needle bearing was related to the density of lubricant, rotational speed, as well as the angle and size of oil hole, rather than the position of the oil holes; Moreover, the centrifugal force F on the needle roller bearing at input shaft was related to the speed of transmission gear and was also associated with the clearance size between needle roller and cage. Theoretical analysis, simulation, and experimental results have demonstrated that the lubrication performance of needle roller bearings during operation at lower rotary speed gears was inferior to that at higher speed gears, and the lubrication was also less effective when the cage clearance was narrower. Employing angled oil inlets (holes), appropriately enlarging the diameter of oil inlets (holes), and increasing the clearance width between needle roller and cage will contribute to the improvement of lubrication effect.

Failure Analysis of a Welded Block Valve and Reducer

Failure Analysis of a Welded Block Valve and Reducer

Uranium Mine Proposed Experimental Design for Natural Background Gross Gamma Exposure Rates, Post Remediation Final Status Survey Sampling Density, and Radiological Water Quality Modeling for a Worst-case Catastrophic Failure, Coles Hill, Virginia.

Completely randomized experimental design statistical modeling techniques were employed to analyze exposure rate measurements for evaluating hypothetical natural background post uranium mill operations at Coles Hill, Virginia uranium milling processes. The proposed Coles Hill Uranium Mine is situated upstream of the Banister River. This River is nearly homogenous throughout the reach length used in analysis and feeds into the mouth of Kerr Reservoir, Lake Gaston, which serves as the main drinking water source for cities in the Hampton Roads area including Norfolk, Virginia Beach, and Chesapeake. A critical scan value (=DCGLscan) was developed to flag anomalies of surface contamination during simulated post remediation final status surveys. The natural background was critical for meeting the Multi-Agency Radiation Survey and Site Investigation Manual guidance for post remediation final status surveys. The overarching null hypothesis suggested that the selected mean natural background is equal to the survey unit's mean natural background. Using SAS Procedures Shapiro-Wilk Test, ANOVA, and CR, it was decided the exposure rate data was normal, had no extreme outliers, and no collinearity between the number of samples (=treatment) and the areas (=block). Using the q-hyper (hypergeometric) distribution, the soil sampling density was decided for a final status survey unit. The most likely worst-case catastrophic failure analysis, 500-year event, such as the1969 Hurricane Camille of 69 centimeters of rain in Nelson County, Virginia was included in the model. The model showed impact was minimal at most to the Banister River's drinking water and likely less than the Virginia's Drinking Water Standards for gross alpha, 226Ra and 228Ra, and total uranium.

Experimental characterisation framework for laminate free edges by Digital Image Correlations and validation of numerical predictions

This paper develops an accurate experimental framework to measure interlaminar strains on laminate free edges. Digital Image Correlation (DIC) is used with an ultra-fine speckle pattern and macro lens to resolve strain fields with a resolution of ∼ 15 µm, allowing for through-thickness deformation and strain mapping. Data analysis techniques are developed to denoise the strain field and discount the effect of random local fibre distribution.The major application of the framework is to validate numerical predictions, and it is demonstrated on angle-ply laminates over a range of ply orientations. A micropolar-based finite-element approach was compared to both a classical finite-element approach and the DIC-acquired interlaminar strain fields. Key improvements by the results include significantly overcoming the stark inconsistency of classical normal strains, and reducing the discrepancies of shear strains from 30 % to 3 ∼ 10 %. The outcomes can be extended to destructive failure analysis and the free-edge study of various other composite architectures.

Regularized Density-Driven Damage Mechanics Model for Failure Analysis of Cementitious Composites

Regularized Density-Driven Damage Mechanics Model for Failure Analysis of Cementitious Composites