Failure Mechanisms Research Articles

Investigation of the Failure Mechanism and PTFE Strength Reduction of Double-Layer Orthogonal Cable-Membrane Connections

Investigation of the Failure Mechanism and PTFE Strength Reduction of Double-Layer Orthogonal Cable-Membrane Connections

Shear strength model of FRP-reinforced concrete beams without shear reinforcement

The current design codes for evaluating the shear strength of concrete beams reinforced with fiber-reinforced polymer (FRP) bars predominantly rely on a semi-empirical approach through test data calibration without a robust theoretical background. This approach may lead to either overestimation or underestimation, resulting in significant scattering in strength predictions. This study proposed a modified approach to enhance the existing unified shear-strength model developed for steel-reinforced concrete (RC) beams based on the compression zone failure mechanism, for predicting the shear strength of FRP-RC beams without shear reinforcement. The proposed model integrates strain and stress approaches, accounting for the distinctive characteristics associated with FRP reinforcement. Additionally, the overall shear resistance capacity of the FRP-RC beam is considered as the sum of contributions from the intact concrete of the compression zone and the aggregate interlock mechanism. The reliability of the proposed model is verified by comparing its predictions with a comprehensive database comprising 264 FRP-RC beam specimens without shear reinforcement reported by 41 research groups. Furthermore, the accuracy of the proposed model was assessed through a comparative analysis with existing evaluation methods, encompassing machine learning-based models, empirical models, theoretical models, and design codes. The results indicate that the proposed model satisfactorily predicts the shear strength of FRP-RC beams within a wide range of design parameters. In comparison with machine learning-based models, the proposed theoretical model exhibits a similar level of accuracy in terms of the mean shear strength ratio and coefficient of determination (R2) values but with less scattering, indicated by lower coefficient of variation (COV) and root mean square error (RMSE) values. In addition, the proposed model outperforms existing empirical and theoretical models, as well as current design codes, by significantly enhancing prediction accuracy, demonstrated by lower COV, RMSE, and higher R2 values. Finally, a parametric study was conducted to investigate the effects of the key parameters on the shear strength of FRP-RC beams using both the proposed model and representative existing evaluation methods.

A Comprehensive Understanding of Thermal Barrier Coatings (TBCs): Applications, Materials, Coating Design and Failure Mechanisms

A Comprehensive Understanding of Thermal Barrier Coatings (TBCs): Applications, Materials, Coating Design and Failure Mechanisms

Effect of corrosion pit on fatigue damage and failure in powder bed fusion AlSi10Mg

AbstractThis paper is concerned with environmental corrosion during service of load‐bearing aluminum alloys fabricated by additive manufacturing (AM) with a focus on damage evolution characterization and identification of dominated failure mechanisms of pre‐corroded selective laser melted aluminum alloy. An experimental strategy for analysis of the damage and failure process is presented, combining 3D surface measurement, 3D digital image correlation, and scanning electron microscopy, to provide a multi‐source experimental characterization of corrosion morphology, strain field evolution, and fracture morphology. Statistics and machine learning methods were employed to process the measured multi‐source experimental data, showing that local average roughness has a strong influence on macro‐crack initiation position. The analysis focuses on four primary types of fatigue micro‐crack initiation, namely, internal defect, diffuse corrosion, corrosion micro‐pit, and corrosion jut; internal defect and diffuse corrosion are unique features for powder bed fusion (PBF) AlSi10Mg. The micro‐crack initiation mechanisms for all four types are (i) local stress concentrations due to adjacent material micro‐structural defects, (ii) interaction of underlying alloy microstructure and corrosion‐induced stress/strain, and (iii) local stress/strain concentration at corrosion micro‐pit and jut, respectively.

Piston ring and cylinder liner scuffing analysis in dual-fuel low-speed engines considering liner deformation and tribofilm evolution

The piston ring and cylinder liner (PRCL) system in larger-bore low-speed marine engines frequently experiences scuffing failures, which significantly decrease the engine reliability. To understand this failure mechanism, a scuffing failure model subjected to the PRCL system was developed considering multidisciplinary coupling effects that integrate asperity contact, hydrodynamic lubrication, tribochemistry reactions, thermal effects, friction, and surface wear. The impacts of large-scale deformation and gas-combustion mode on the scuffing performances of the PRCL system were examined. The key findings indicate that the larger-scale liner deformation can markedly reduce oil film thickness and exacerbate local asperity contact, influencing the evolution of the tribofilm by increasing the removal process. Under gas-combustion mode, the oil film thickness is even lower, and the asperity contact pressure further increases due to a more starved lubrication state and higher combustion temperature. This leads to tribofilm breakdown and severe wear near the ring opening area, which are aligning with the full-scale experimental results with scuffing failure.

Effect of ductility of flush end-plate connections on the behaviour of MRFs under fire conditions: An experimental study

The performance of beam-to-column connections is a key factor in the behaviour of moment-resisting frames (MRFs) under fire conditions. In this work, the behaviour and failure mechanisms of a half-scale 3D frame, composed of single-bay, single-storey MRFs and Braced Frames, in two perpendicular planes, equipped with 6 mm thick flush end-plate connections, under fire conditions was studied. A ‘scaled’ ISO 834 standard fire curve was followed during fire loading of the frame. The maximum reached temperature was 1100 °C. The temperatures of the elements of frames were measured at 2-minute time intervals. The rotations of the connections and the deflections of the MRFs’ beams at these time points were worked out using an image processing technique. Furthermore, the effect of the ductility of connections was investigated by comparing the results of this study with those of a previous one in which less ductile connections were used. The results showed that the connections used in this study could sustain large rotations of up to 0.7 radian and endure 65 min under fire. Moreover, it was found that using flexible connections (connections with thinner end-plates) enhances the ‘robustness’ of moment frames in fire.

Effect of Mineral Composition and Particle Size on the Failure Characteristics and Mechanisms of Marble in the China Jinping Underground Laboratory

In deep underground engineering, the deformation, failure characteristics, and mechanism of surrounding rock under the influence of grain sizes and mineral compositions are not clear. Based on CJPL-II variously colored marbles, the differences in grain size and mineral composition of the marble were analyzed by thin-section analysis and XRD tests, and the effect of intermediate principal stress on the mechanical properties of marble was investigated. Both SEM and microfracture analysis were coupled to reveal the failure mechanisms. The results highlight that the crack initiation strength, damage strength, peak strength, and elasticity modulus of Jinping marble exhibit an increasing trend with an increase in intermediate principal stress, while the peak strain initially increases and subsequently decreases. Moreover, this study established negative correlations between marble strength, brittleness characteristics, and fracture angle with grain size, whereas positive correlations were identified with the content of quartz, sodium feldspar, and the magnitude of the intermediate principal stress. The microcrack density in marble was found to increase with larger grain sizes and decrease with elevated quartz and sodium feldspar content, as well as with increasing intermediate principal stress. Notably, as the intermediate principal stress intensifies and grain size diminishes, the transgranular tensile failure of marble becomes more conspicuous. These research findings contribute to the effective implementation of disaster prevention and control strategies.

Bolt-Hole Elongation of Woven Carbon-Epoxy Composite Plates and Joints Using the Digital Image Correlation Technique

The elongation of the bolt hole is an important parameter for assessing the failure of bolted joints. However, direct experimental measurement using strain gauges and extensometers is difficult. This article shows that digital image correlation (DIC) can overcome the difficulties and provide important indications of the failure mechanisms of bolted joints. Hole elongation was measured using DIC in the following carbon/epoxy composite configurations: standard open-hole tensile (OHT) and filled-hole tensile (FHT), single-lap shear only-bolted (OB), and single-lap shear hybrid-bolted/bonded (HBB) joints. For each configuration, the hole-elongation changes were tracked for cross-ply (CP) and quasi-isotropic (QI) stacking sequences with two thicknesses. In the tensile load direction for OHT and FHT cases, CP showed a greater hole elongation than QI. However, the opposite trend was observed in the transverse direction. In OB joints, bypass loads contributed more to the hole elongation than bearing action. In HBB joints, it has been observed that the adhesive significantly reduces hole elongation, particularly for CP configurations. Moreover, it was found that in HBB joints, hole elongation was independent of laminate lay-up, while it was very determinative in OB joints.

The research on the failure mechanism and dynamic reliability of lubricated clearance

In the operation of mechanisms with lubricated clearances, uncertain parameters such as the temperature of lubricant, driving speed, and clearance value will lead to dynamic variations for oil film thickness of lubricated clearance. The lubrication may fail when the oil film thickness of bearing surfaces is insufficient, thereby significantly affecting the performance of the mechanism. This paper presents a novel method for the dynamic reliability of lubricated clearances by improved response surface method (IRSM). Firstly, the mathematical model of lubricated clearance is established, and the oil film load of lubricated clearance is defined, then the dynamic model of mechanism considering lubricated clearances is built through Lagrange method. Secondly, considering the failure mechanism of the lubricated clearance, the surrogate model is established using the IRSM with minimum oil film thickness as the failure criterion. Finally, taking the 9-link mechanism with multiple lubricated clearances as a numerical example, the dynamic minimum oil film thickness of the lubricated clearance considering uncertain parameters is computed. The reliability of the lubricated clearance is investigated by the surrogate model, and the applicability of the model is verified by the Monte Carlo method (MCM). The results demonstrate that the IRSM has higher accuracy compared to the traditional response surface method (TRSM). This paper provides a theoretical basis for the study of failure mechanism and reliability of lubricated clearances, and also has practical significance for engineering applications.

Investigation on mechanical and thermal behaviour of graphene bonded carbon/Kevlar hybrid fabric polymer composites

The present research is aimed to understand the influence of graphene-reinforced carbon/Kevlar hybrid fabric epoxy composites. Samples HG0, HG2, HG4, and HG6 are fabricated using four layers of fabric mat and with varying graphene weight percentage as 0, 2, 4, and 6 wt.%, respectively. Mechanical characterizations such as hardness, tensile, and flexural strength were individually assessed. Thermal stability is evaluated through thermos-gravimetric analysis. Composite HG6 with high filler loading showed 71% and 114.4% greater tensile and flexural strength compared to unfilled HG0 specimen. Similarly, HG6 exhibited greater thermal stability. Inclusion of graphene particles in higher concentration improved the interfacial bonding between fibre/matrix/filler system. Fracture surfaces are analysed using scanning electron microscopy to understand the failure mechanisms.

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.