Failure Mechanisms Research Articles

Infrared temperature evolution law and thermal effect mechanism of concrete impact failure

Concrete impact failure can occur quickly and cause severe failure, which is of great significance for effective monitoring of concrete impact failure. Infrared thermal imaging technology possesses the merits of high sensitivity, noncontact, and nondestructive monitoring, rendering it extensively employed in monitoring the stability of concrete structures. However, the infrared radiation temperature (IRT) evolution law and thermal effect mechanism of concrete impact failure are not clear at present. In this study, infrared monitoring experiments were conducted on concrete impact failure and static load failure using drop hammer (DH) testing machines, pressure testing machines, and infrared thermal imagers. The infrared thermal images and the IRT change law of concrete subjected to DH impact failure were analysed. The infrared thermal effect difference and mechanism between DH impact and static load failure were compared. The results indicate that there is an infrared high-temperature point at the impact location of concrete DH impact failure, and both average infrared radiation temperature (AIRT) and maximum infrared radiation temperature (MIRT) increase suddenly. The increase in the MIRT is tens of times that of the AIRT. Compared with that of static load failure, the infrared high-temperature area of concrete DH impact failure is concentrated, while the IRT of static load failure increases overall, and the heating area is large. Moreover, the change in the IRT under DH impact failure is much greater than that under static load failure. The infrared thermal effect of concrete under DH impact failure was mainly composed of the thermoelastic effect, frictional thermal effect and tensile failure endothermic effect. The infrared data obtained for concrete impact failure should focus on the highest and lowest IRT change indicators. The highest IRT corresponds to the impact failure point, and the lowest IRT corresponds to the tensile failure position. The research results provide a new infrared thermal effect approach for monitoring the stability of concrete under impact failure.

Manipulating Local Chemistry and Coherent Structures for High-Rate and Long-Life Sodium-Ion Battery Cathodes.

Layered sodium transition-metal (TM) oxides generally suffer from severe capacity decay and poor rate performance during cycling, especially at a high state of charge (SoC). Herein, an insight into failure mechanisms within high-voltage layered cathodes is unveiled, while a two-in-one tactic of charge localization and coherent structures is devised to improve structural integrity and Na+ transport kinetics, elucidated by density functional theory calculations. Elevated Jahn-Teller [Mn3+O6] concentration on the particle surface during sodiation, coupled with intense interlayer repulsion and adverse oxygen instability, leads to irreversible damage to the near-surface structure, as demonstrated by X-ray absorption spectroscopy and in situ characterization techniques. It is further validated that the structural skeleton is substantially strengthened through the electronic structure modulation surrounding oxygen. Furthermore, optimized Na+ diffusion is effectively attainable via regulating intergrown structures, successfully achieved by the Zn2+ inducer. Greatly, good redox reversibility with an initial Coulombic efficiency of 92.6%, impressive rate capability (86.5 mAh g-1 with 70.4% retention at 10C), and enhanced cycling stability (71.6% retention after 300 cycles at 5C) are exhibited in the P2/O3 biphasic cathode. It is believed that a profound comprehension of layered oxides will herald fresh perspectives to develop high-voltage cathode materials for sodium-ion batteries.

Progressive Failure Mechanism of Shield Tunnel Face in Complex Urban Geological Environment

The construction of multiple tunnels across inland rivers has had a significant influence on the improvement of the transportation infrastructure. The technology for constructing tunnels is progressing towards the development of larger cross-sections, longer distances, and the ability to withstand high hydraulic pressure in complex hydrogeological conditions, including high-permeability strata. In order to ensure the face stability of shield tunnels under high hydraulic pressure that crosses a fault fracture zone, it is necessary to study the progressive failure mechanism of shield tunnel faces induced by high hydraulic pressure seepage. This paper employs finite element numerical simulation software to methodically examine the variation in the characteristics of the water seepage field, limiting support force, and face stability failure mode of shield tunnels passing through fault fracture zones with high hydraulic pressure under varying fault fracture width zones. The results show that the formation hydraulic gradient will progressively widen when the tunnel face is located within the undisturbed rock mass and is advanced towards the area of fault fracture. This will raise the likelihood of instability in the shield tunnel and progressively raise the limiting support force on the tunnel face. Moreover, as the tunnel face nears the region of fault fracture within the undisturbed rock mass, the damage range increases gradually. In addition, due to the increase in seepage force, the angle between the failure area and the horizontal plane becomes more and more gentle. On the contrary, as the tunnel’s face moves closer to the undisturbed rock mass from the region of the fault fracture, the damage range gradually decreases, and the dip angle between the damage area and the horizontal plane becomes steeper and steeper due to the decreasing seepage force in the process. The study findings presented in this work are highly significant, both theoretically and practically, for the design and management of safety.

Investigating the failure mechanism of X-shaped non-persistent joints under uniaxial loading: Experimental and numerical analysis

In this paper, rock samples containing non-persistent cracks of ‘‘X’’- shape were prepared and experimentally studied under uniaxial compression. Then, the numerical simulations of these tests were established using dynamic finite element software (LS-DYNA). Various joint configurations are assumed and their lengths are considered to change from the center of “X” in different rock specimens. The cracks propagation patterns, the failure processes, and energy absorptions during the tests are studied. The gypsum samples’ dimensions were 10 × 10 × 5 cm and one “X” shaped non-persistent crack was provided inside each specimen. The tensile strength of gypsum samples was 1 MPa. The notch's lengths are similar in some three cases while the length of one wing of the crossest joint varied in two other cases. In two residual cases, the length of the two wings of the crossest joint was varied. The opening of the crack was 1 mm. Angel between the notch trajectories was 90°. The model was subjected to an applied axial load rate of 0.05 mm/min. Results show that the failure mechanism of specimens was affected by notch length. The larger notch has a dominant effect on the breakage mode and failure strength. Newborn tensile cracks originated at the notch tip and propagated parallel to the loading axis to merge with the model boundary. Both the crack initiation stress and breakage stress were decreased by increasing the notch length. The absorbed energy has a minimum value when two large notches with a length of 6 cm exist in the model while it has a maximum value when notch lengths are equal to 2 cm. The increase in notch length resulted in a decrease in the difference between strains associated with crack initiation stress and final stress, indicating progressive breakage. Whereas the difference between strains associated with crack initiation stress and final stress was increased by decreasing the notch length, therefore delay failure occurred after crack initiation in the model. The results obtained from both laboratory experiments and numerical simulations show good agreement in the failure progression.

A Numerical Study on Predicting Bond-Slip Relationship of Reinforced Concrete using Surface Based Cohesive Behavior

Overall structural integrity and load transfer between concrete and reinforcement enabling composite action relies on the bond between concrete and reinforcement. Bond strength determination of reinforced concrete is an essential task that a pullout test can determine. Experimental pullout behaviour can be affected by various parameters, such as concrete and steel strength, boundary conditions, etc. Therefore, a parametric study on pullout tests is time-consuming. In addition, measurements of internal stress-strain components and damages of constitutive materials are also difficult in experimental endeavours. In this context, finite element (FE) models should be developed to perform a parametric study with cost and time-saving. This study proposes a finite element modeling strategy of reinforced concrete under pullout force by using the expected failure mechanism to predict bond-slip behaviour in ABAQUS. In FE models, surface-to-surface cohesive interaction behaviour was used to assign interaction between reinforcement and concrete. The proposed modelling strategy was validated with available experimental data from four reference specimens, having all possible failures (i.e., pullout, splitting, and splitting-pullout) under pullout loading. The finite element analysis showed that the proposed FE modeling strategy performed well in predicting bond-slip behaviour in elastic regions. Additionally, maximum bond stresses were predicted satisfactorily, except for the splitting failure pattern, using the proposed FE modelling strategy.

Ballistic resistance of 7XXX laminate aluminum alloy plates and base alloys subjected to different projectiles

The ballistic impact of two 7XXX aluminum alloys, 7A52-T6 and 7A62-T6, as well as their combination in a 7B52 laminate plate, was simulated and experimentally tested. Three types of projectiles were utilized hard ogival nosed, hard blunt nosed, and 304 steel core projectiles to investigate the ballistic resistance and failure mechanisms of the aluminum alloy targets. Additionally, an existing modified Gurson-Tvergaard-Needleman (GTN) model incorporating shear, void growth, and spalling failure mechanisms, was employed to simulate the ballistic impact process, utilized to analyze energy dissipation during impact. The results reveal that the 7A52 alloy only experiences ductile hole expansion failure, whereas the 7A62 high-strength aluminum alloy undergoes spalling and fragmentation subsequent to penetration, leading to potential impact hazards. Due to its backing layer being the highly ductile 7A52 alloy, the laminate plate will not produce fragments after penetration. The improved GTN model provided better predictions of the impact failure modes of the aluminum alloys. Concerning impact performance, when subjected to hard ogival projectiles, the laminate alloy did not enhance material impact resistance. However, when impacted by blunt-nosed projectiles, the laminate alloy exhibited a 27 % improvement over the 7A52 plate and an 11.9 % increase over the 7A62 plate. Furthermore, when impacted by 304 steel core ogival projectiles, the laminate alloy demonstrated over a 41.3 % improvement compared to the 7A52 plate and over a 15.5 % increase compared to the 7A62 plate. The laminate plate's high ballistic performance was attributed to the increased plastic deformation energy after spalling failure, while ensuring high energy absorption during ductile hole expansion penetration.

Influence of the Pd Oxidation State in PdNi Thin Films on Surface Acoustic Wave Hydrogen Sensing Performance.

PdNi alloy thin films demonstrate exceptional hydrogen sensing performance and exhibit significant potential for application in surface acoustic wave (SAW) hydrogen sensors. However, the long-term stability of SAW H2 sensors utilizing PdNi films as catalysts experiences a substantial decrease during operation. In this paper, X-ray photoelectron spectroscopy (XPS) is employed to investigate the failure mechanisms of PdNi thin films under operational conditions. The XPS analysis reveals that the formation of PdO species on PdNi thin films plays a crucial role in the failure of hydrogen sensing. Additionally, density functional theory (DFT) calculations indicate that hydrogen atoms encounter a diffusion energy barrier during the penetration process from the PdNiOx surface to the subsurface region. The identification of PdNi film failure mechanisms through XPS and DFT offers valuable insights into the development of gas sensors with enhanced long-term stability. Guided by these mechanisms, we propose a method to restore the hydrogen sensing response time and magnitude to a certain extent by reducing the partially oxidized surface of the PdNi alloy under a hydrogen atmosphere at 70 °C, thereby restoring Pd to its metallic state with zero valence.

Erratum to: Uniaxial Compression Testing of Sandstone under Microscope:Damage Characteristics and Failure Mechanisms

Erratum to: Uniaxial Compression Testing of Sandstone under Microscope:Damage Characteristics and Failure Mechanisms

Tension and Shear Behaviour of Basalt Fiber Bio-Composites with Digital Image Correlation and Acoustic Emission Monitoring.

This research investigates the mechanical behavior and damage evolution in cross-ply basalt fiber composites subjected to different loading modes. A modified Arcan rig for simultaneous acoustic emission (AE) monitoring was designed and manufactured to apply quasi-isotropic shear, combined tensile and shear loading, and pure tensile loading on specimens with a central notch. Digital image correlation (DIC) was applied for high-resolution strain measurements. The measured failure strengths of the bio-composite specimens under different loading angles are presented. The different competing failure mechanisms that contribute to the local reduction in stress concentration are described. Different damage mechanisms trigger elastic waves in the composite, with distinct AE signatures that closely follow the sequence of fracture mechanisms. AE monitoring is employed to capture signals associated with structural damage initiation and progression. The characteristic parameters of AE signals are correlated with crack modes and damage mechanisms. The evolution of AE parameters during the peak load transition is presented, which enables the timely AE detection of the maximum load transition. The combination of DIC and AE monitoring improves understanding of the mechanical response and failure mechanisms in cross-ply basalt fiber composites, offering valuable insights for possible performance monitoring and structural reliability in diverse engineering applications.

Strength design of built-up radially battened columns subject to axial compression and arbitrary directional bending moment

Built-up radially battened columns (RBCs), comprising several identical circular steel tubes interconnected by multiple radial-shaped battens, represent an innovative column design that combines aesthetic appeal with exceptional load-bearing capacity. This makes them well-suited for architectural applications in large public buildings such as stations and airports. The axial compressive strength design methods for the built-up RBC have been extensively explored in the authors' prior studies. However, in real-world engineering applications, built-up RBCs may experience simultaneous axial compression and varying directional bending moments, particularly when considering potential eccentric compression or wind and earthquake loads in public buildings. Currently, strength design methods for this loading condition are still lacking. To address this deficiency, this paper primarily delves into the failure mechanism and strength design methods for built-up RBCs experiencing combined axial compression and arbitrary directional bending moments. Initially, the sectional strength of the built-up RBC is investigated by using a shell finite element model (FEM) for the built-up RBC. It is revealed that the compression-bending sectional strength of the built-up RBC exhibits significant differences with varying bending directions and tube numbers. Moreover, in some bending directions, the M-N sectional strength curve of the built-up RBC exhibits convexity. By integrating theoretically derived equations grounded in the principles of materials mechanics with FEM numerical calculations, concise and practical design equations are proposed for accurately predicting the sectional strength of the built-up RBC under combined axial compression and arbitrary directional bending moments. Subsequently, The buckling strength of the built-up RBC is studied using the FEM, considering initial geometrical imperfections consistent with first-order flexural buckling and accounting for geometric nonlinearity. It is noted that the bending direction of the built-up RBC may deviate during loading. Besides, the M-N buckling strength curve of the built-up RBC is not as convex as its M-N sectional strength curve. Based on calculations from numerous examples, practical design equations for predicting the buckling strength for the built-up RBC under axial compression and any directional bending moments are introduced. The key findings of this paper contribute to the compression-bending strength design of RBCs, enriching RBC design theory and promoting the widespread application of built-up RBCs in actual engineering projects.

FRACTAL CHARACTERISTICS OF CORE DISKING FRACTURE SURFACES

The morphological characteristics of core disking can reflect the in-situ stress field characteristics to a certain extent, but a quantitative description method for disking-induced fracture surfaces is needed. The fractal geometry was introduced to refine the three-dimensional characteristics of the core disking fracture surfaces, and the disking mechanism was explored through morphological characteristics. The innovative concentric-different scale method was proposed to divide the circular surfaces into square surfaces of different sizes. Furthermore, the applicability of four cubic covering methods for single fractal calculation was studied. Finally, the relative differential cubic covering method and multifractal method were used to calculate the three-dimensional data of core disking fracture surfaces in the Jinping area. The results showed that the concentric-different scale method fits the fractal dimension changing law in the exploration of different surface sizes. Using the differential cubic covering method and the relative differential cubic covering method can obtain good results for smoother surfaces. The disking was caused by tensile stress due to high crustal stress unloading, and the cracks originated from the inside of the core. Fractal theory is conducive to analyzing the morphology of rock fracture surfaces and provides guidance for exploring the failure mechanism and influencing factors.

Reliability analysis of rolling bearings considering failure mode correlations

AbstractAs an essential mechanical component, a rolling bearing can exhibit multiple failure modes that may occur independently or in correlation with one another. A reliability analysis method that meticulously accounts for the interdependencies among various bearing failure modes is presented in this paper. The examination of wear and fatigue failure mechanisms in rolling bearings is carried out using the Physics of Failure (PoF) approach. By considering the influence of uncertain variables, the limit state functions for individual failure modes are formulated through the application of stress‐strength interference theory. In the context of wear failure, the limit state function is derived using working clearance as the characteristic quantity. On the other hand, the limit state function for fatigue failure is constructed with a focus on fatigue damage accumulation. The Copula function is used to characterize the relationship between wear failure and fatigue failure, and a reliability calculation model for rolling bearings is developed, considering the correlation between these failure modes. Ultimately, the proposed method is utilized to assess the reliability of bearings under two different sets of test conditions. The feasibility of this method is confirmed through test data, demonstrating its effectiveness in predicting bearing reliability. Through the application of this method, engineers can optimize bearing size parameters, select appropriate initial clearances, and enhance the reliability design of bearing.

A ductile seismic design strategy for the cross-aisle direction of racking systems

AbstractDue to their lightness and simple connectivity, steel racking systems are typically considered as “low-dissipative” structures, which is reflected in the modern seismic codes by the absence of capacity design and the adoption of low behaviour factors. This limited capability of stress redistribution significantly increases the vulnerability of racks under beyond-design seismic hazards and raises the demand for more resilient designs. Along these lines, the proposed Plastic Ovalization Strategy (POS) attempts to increase the ductility of the individual upright frames comprising the cross-aisle direction of racks, and at the same time to preserve their low-cost and easy-to-assemble nature. This is achieved by tasking the bearing failure mechanism of the diagonal bolt hole to absorb seismic deformations, while capacity design is employed to keep the rest of the structure in the elastic zone. Following a detailed discussion on the motives and basic principles of the strategy, two high-rise racking systems are designed twice by professional engineers, once using standard approaches and then by additionally employing the proposed POS rules. Finally, the two design solutions are compared by conducting a comprehensive seismic assessment, which employs a phenomenological macro-model comprising elastic elements and nonlinear springs to simulate the bearing failure mechanism.

Microcracking in On-Chip Interconnect Stacks: FEM Simulation and Concept for Fatigue Test

AbstractThe semiconductor industry is continuing the scaling down of both device and on-chip interconnect features, for performance and economic reasons. This trend has implications for the design of guard ring structures, i.e. metallic non-functional structures in the back-end-of-line (BEoL) stack designed to be efficient to stop microcracks. In this work, we present a sample design for an in situ experiment to study mechanical degradation and failure mechanisms of crack stop structures in the BEoL stack, to ensure the mechanical robustness of microchips for future technology nodes. Additional finite element method (FEM) simulations provide supplementary understanding of the crack kinetics. To examine the effects of mechanical loading on crack stop elements of the BEoL stack, a novel sample geometry for an in situ fatigue experiment using x-ray microscopy was developed. The x-ray microscope (ZEISS Xradia 800 Ultra) enables high-resolution imaging of the 3D-patterned sample structures and defects such as microcracks. The tailored sample geometry allows the application of a tensile load to a BEoL specimen by a lever mechanism. The feasibility of the sample design is shown by mode-I loading of a pure interconnect sample. Post-mortem analysis by scanning electron microscopy (SEM), confirming planar microcrack propagation from the notch through the dielectric layer with small deflections of the crack path near cone shaped copper vias. FEM simulations focusing on the stress-strain fields around a crack tip indicate the beginning of copper plasticity as major mechanism starting the redirection of cracks due to resulting material compression in front of the obstacle.

Effect of surface rolling process on rolling contact fatigue behavior and failure mechanism of powder metallurgy steel

The effect of surface rolling process on the surface microstructure and rolling contact fatigue of the Fe-2Cu-0.6 C powder metallurgy steel was investigated in the present investigation. Results indicated that a densified and hardened layer with a densification depth of 330 μm and a surface hardness of 330 HV0.1 was generated in the surface layer after rolling process. Ferrite grain and pearlite lamellae became typical fibrous structures on the top surface. The microstructure of pearlite was presented by two typical features. One was that the discrete cementite plates were severely curled and wavy. The other one was that the cementite plates remained parallel to each other, but were a reticular structure at a macroscopic level. The rolling contact fatigue (RCF) test showed that the RCF life of the rolled sample was superior. The L10, L50, L63.2 life increased by 182%, 105%, 92%, respectively. Surface initiated spalling was the main fatigue failure mode. Subsurface equivalent contact stress and local equivalent stress were calculated. The results showed that surface cracks were due to the repetitive tensile stress, which caused pits. Subsurface cracks nucleated and propagated in the region where the local equivalent stress was higher than the matrix yield strength, which caused spalling as connecting with surface cracks. The surface densified layer plays an important role in improving the rolling fatigue resistance of the material.

Experimental analysis of 3D printed continuous carbon/glass hybrid fiber reinforced PLA composites: Revealing synergistic mechanical properties and failure mechanisms

AbstractThis study investigates the mechanical properties of continuous carbon/glass hybrid fiber‐reinforced polylactic acid (PLA) composites (HFRC) produced through the three dimensions (3D) printing process, comparing them with single carbon fiber‐reinforced PLA composites (CFRC). Initially, composite prepreg filaments are prepared using an impregnation device, followed by fabrication using a 3D printer. The mechanical performance results reveal a 13% increase in tensile strength for HFRC compared with CFRC. Due to differing elongation rates of carbon and glass fibers, HFRC exhibits two strength peaks, while CFRC demonstrates a 37% higher bending strength than HFRC. Scanning electron microscope images indicate that the tensile failure mechanism involves fiber brittle fracture and fiber‐matrix interface debonding, while the bending failure mechanism includes fiber pullout, fiber debonding, fiber cluster buckling, and interlayer interface failure.Highlights To realize the moldless rapid manufacturing of continuous hybrid fiber‐reinforced PLA composites. The stress–strain curves of single fiber‐reinforced composites and hybrid fiber‐reinforced composites are obviously different. Elucidating the effect of single fiber/hybrid fiber in composites on mechanical properties and failure mechanism according to micro‐morphology.

Quantifying the Growth Kinetics of Lithium Metal Reduced from Solid Ionic Conductors.

Investigating the growth kinetics of Li metal in solid-state batteries is crucial to both a fundamental understanding and practical application. Here, by directly observing the formation of Li metal from Ta-doped Li6.4La3Zr1.4Ta0.6O12 (LLZTO) in a transmission electron microscope, the growth kinetics is analyzed quantitatively. The growth kinetics of Li deposits shows a cubic-curve characteristic for LLZTO with Li-source-free. Instead, a linear growth process is observed with Li-source supplied. The impact of the illuminating electron dose rate on the growth kinetics is clarified, indicating that even low dose rates (1-3 e-/Å2/s) could affect Li growth, highlighting the significance of controlling dose rates. Furthermore, a new pathway for the formation of Li metal from Li-containing materials utilizing the field-emission effect is reported. This work has implications on the failure mechanism in solid batteries by using limited Li anodes and opens pathways for regulating Li growth in LLZTO at various scenarios, which can also extend to other ionic conductors.

Large-Scale Laboratory Experiments On The Wave Generation Due To The Collapse Of Partially And Fully Submerged Granular Columns

Landslides that occur in coastal environments can drive cascading consequences such as wave forces, flooding, and infrastructure damage to coastal communities. It can be difficult to classify these slides as subaerial or submarine, and the mechanics of wave generation associated with partially submerged failures are not well understood. Limited physical modelling has been conducted that encompasses both the triggering of granular landslides and subsequent waves associated with partially and fully submerged mass movements. To date, laboratory work investigating tsunamis generated by submarine landslides has focused on the wave formed in the direction of the mass movement (seaward direction) for rigid block experiments (eg. Rzadkiewicz, 1997) and deformable slide masses (e.g. Grilli et al., 2017, Takabatake, 2020, Bullard et al., 2023). From these experimental data sets, predictive relationships connecting slide acceleration, mass, and initial submergence depth to the amplitude of the wave formed have been presented for the seaward wave. Such relationships have not been presented for the landward directed wave, which propagates in the opposite direction of the submarine landslide motion. Further, not all landslides are easily classified as either subaerial or submarine. Consider the 2018 Anak Krakatoa landslide in which the sliding surface was estimated to be 100 m below sea level (Pakoksung et al., 2020), resulting in one third of the total collapse being submerged. In comparison to the end-member conditions of subaerial and submarine failures, the mechanics of wave generation associated with partially submerged failures is much less clear. Granular column collapse experiments provide an idealized experimental framework to explore momentum transfer processes and the resulting waves generated in partially submerged and fully submerged conditions. Work by Cabrera et al., (2020) made use of granular collapse experiments of partially to fully submerged columns to derive a continuous momentum-based function to estimate the maximum seaward wave amplitude based on the initial column submergence ratio (Hw/Ho). However, these experiments were conducted at a small-scale (Ho = 0.15 m) with a width of one particle (2.4 mm diameter). To address this research gap, a series of 22 large-scale granular collapse experiments were conducted by releasing columns of river stone (0.75 m and 0.50 m high) into a laboratory flume reservoir with water depths ranging up to 1.10 m to explore the wave generation and runup processes in both seaward and landward directions. The columns were released by a rapid pneumatically actuated vertical rising gate designed to enable the near instantaneous loss of support of the source volumes resulting in granular collapse. The failure mechanics were captured with high-speed cameras (Figure 1a,b) and wave amplitudes were measured using wave capacitance gauges (Figure 1c,d). This work also provides the first experimental data set of the landward propagating wave and runup associated with submerged granular collapse experiments. Overall, the seaward wave amplitudes measured in these highly-instrumented, large-scale physical models agree with empirical relationships developed in a previous study using smaller-scale models.

Advancing Smart Lithium-Ion Batteries: A Review on Multi-Physical Sensing Technologies for Lithium-Ion Batteries

Traditional battery management systems (BMS) encounter significant challenges, including low precision in predicting battery states and complexities in managing batteries, primarily due to the scarcity of collected signals. The advancement towards a “smart battery”, equipped with diverse sensor types, promises to mitigate these issues. This review highlights the latest developments in smart sensing technologies for batteries, encompassing electrical, thermal, mechanical, acoustic, and gas sensors. Specifically, we address how these different signals are perceived and how these varied signals could enhance our comprehension of battery aging, failure, and thermal runaway mechanisms, contributing to the creation of BMS that are safer and more reliable. Moreover, we analyze the limitations and challenges faced by different sensor applications and discuss the advantages and disadvantages of each sensing technology. Conclusively, we present a perspective on overcoming future hurdles in smart battery development, focusing on appropriate sensor design, optimized integration processes, efficient signal transmission, and advanced management systems.

Faulty machining and micro-segregation assisted fatigue failure of cylinder head stud of a diesel generator

A detailed failure analysis of cylinder head stud bolt of a four-stroke diesel generator has been presented. The study included optical emission analysis, tensile testing, hardness testing, optical microscopy, SEM, and EDX analyses. The investigation showed that the main mechanism of failure was corrosion-fatigue. Fatigue initiation was assisted by pitting corrosion induced by faulty machining, moisture, and presence of tempered martensite and non-metallic inclusions at the surface. Propagation of the fatigue crack was encouraged by localized corrosion within the tempered martensite, non-metallic inclusions, and Mn/Cr/Mo/Si micro-segregation. Both excessive C and Mn/Cr/Mo/Si micro-segregation caused the formation of mixed microstructure of tempered martensite and fresh martensite with retained austenite. The non-uniform microstructure led to non-uniform hardness distribution and caused localized deformation during cyclic loading and promoted fatigue crack propagation.